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CROSS-REFERENCE TO RELATED APPLICATION
This application relates to co-pending application, Ser. No. 08/813,620 (Attorney Reference No: 5000-84200), filed on the same day as the present application and entitled "MICROCONTROLLER HAVING DEDICATED HARDWARE FOR MEMORY ADDRESS SPACE EXPANSION SUPPORTING BOTII STATIC AND DYNAMIC MEMORY DEVICES" by John P. Hansen and Ronald M. Huff, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the manufacture of integrated circuits and more particularly to the manufacture of microcontrollers.
2. Description of the Relevant Art
A microcontroller is an integrated circuit which incorporates a microprocessor core along with one or more support circuits on the same monolithic semiconductor substrate (i.e., chip). A typical computer system includes a microprocessor secured within its own semiconductor device package and connected to several separately-packaged support circuits. The support circuits perform support functions such as communication functions and memory interface functions. Computer systems which employ microcontrollers may thus be formed using fewer semiconductor devices. Advantages of such systems include lower fabrication costs and higher reliabilities. Microcontrollers find applications in industrial and commercial products including control systems, computer terminals, hand-held communications devices (e.g., cellular telephones), photocopier machines, facsimile machines, and hard disk drives.
A microcontroller is typically coupled to one or more external memory devices which store software programs consisting of instructions and data. During operation, the microcontroller fetches the instructions and data from the external memory devices and operates upon the data during instruction execution. The microprocessor core of the microcontroller typically includes an execution unit coupled to a bus interface unit (BIU). The BIU generates multiple address and control signals used to fetch the instructions and data from the external memory devices, and the execution unit executes those instructions. Each unique combination of the address signals generated by the BIU allows access to a different memory location within the external memory devices. For example, if the BIU generates n address signals, the microcontroller may access 2 n unique memory locations.
Due to the widespread acceptance of the x86 microprocessor architecture, many microcontrollers include execution units which execute x86 instructions. While newer microcontrollers incorporate an increased number of support circuits, their execution units remain virtually unchanged in order to maintain backwards compatibility with the vast amount of existing software developed for previous microcontroller products.
There are two basic types of software programs: operating system programs and application programs. An operating system is a collection of software programs which provide file management, input/output control, and a controlled enviromnent for execution of applications programs. MS-DOS® and Windows NT™ (Microsoft Corp.) are common operating systems. An application program is a computer program which performs a specific function, and is typically designed to operate within the controlled environment created by an operating system.
Early x86 microprocessors generate 20 address signals A0-A19. The simultaneous values of the address signals A0-A19 define an address, where A0 is the least significant bit of the binary value of the address and A19 is the most significant bit of the binary value of the address. The 20-bit addresses are generated from a 16-bit "segment" portion and a 16-bit "offset" portion. The segment portion is first shifted four bit positions to the left, then the offset portion is added to the shifted segment portion to form the 20-bit address. With 20 address lines, early x86 microprocessors could generate 2 20 (i.e., 1,048,576) unique combinations of address signals and access 2 20 unique memory locations (i.e., 1,048,576 8-bit bytes of memory, or 1 Mbyte of memory). Newer x86 microprocessors still retain this address generation capability in order to maintain software compatibility. The segment portion is stored in one of several dedicated segment registers which software instructions may read and write. The offset portion is typically generated by the execution unit during instruction execution. Typical microcontrollers based upon the x86 architecture employ this shift-and-add technique to generate 20-bit addresses. The BIU of such microcontrollers typically has special hardware to perform the shift-and-add address generation operation.
The memory address space of a microcontroller generating n address signals extends over 2 n consecutive memory locations from memory location 0 to memory location 2 n -1. For example, the memory address space of a microcontroller having 20 address lines extends from memory location 0 (00000h) to 2 20 -1 (i.e., 1,048,575 or FFFFFh). The x86 architecture places certain restrictions upon the contents of memory locations within the memory address space. The x86 architecture reserves portions of the memory address space having the highest and lowest address values for operating system software. A first portion of the memory address having the highest address values (i.e., the uppermost portion of the memory address space) is reserved for software instructions executed following assertion of a RESET signal, system configuration data, and interrupt service routines executed following the reception of interrupt signals. A second portion the memory address space having the lowest address values (i.e., the lowermost portion of the memory address space) is also reserved for operating system software. The first 1,024 bytes of the memory address space (i.e., memory locations 0 through 1,023 or 003FFh) are reserved for an interrupt vector table including 256 4-byte addresses of the entry points of the interrupt service routines corresponding to received interrupt numbers.
Due to the requirement to reserve the uppermost and lowermost portions of the memory address space, microcontrollers employing the x86 architecture typically include a chip select unit (CSU) which generates separate chip select signals for the uppermost and lowermost portions of the memory address space. The CSU typically also generates one or more chip select signals for a middle portion of the memory address space existing between the uppermost and lowermost portions. Only one chip select signal is asserted at any given time, and only memory devices receiving an asserted chip select signal are enabled for the memory access operation in progress. A first non-volatile memory device (e.g., a ROM or a Flash device) typically contains the portion of the operating system software residing in the uppermost portion of the memory address space and receives the corresponding chip select signal. A second volatile memory device (e.g., a RAM device) typically contains the portion of the operating system software allocated to the lowermost portion of the memory address space and receives the corresponding chip select signal. Additional memory devices may contain application programs, and each additional memory device receives a chip select signal designated for the remaining middle portion of the memory address space.
For example, an x86-based microcontroller may be coupled to three different memory devices: a first 256K×8 Flash memory device, a second 256K×8 SRAM memory device, and a third 512K×8 SRAM memory device. The first memory device has 18 address signal terminals MA0-MA17 and contains the portion of the operating system software residing in the uppermost portion of the memory address space. Terminals MA0-MA17 of the first memory device are connected to address signal terminals A0-A17 of the microcontroller, and the first memory device is enabled by a programmed upper chip select signal (UCS#). Chip select signal UCS# is an active low signal as denoted by the `#` symbol following the signal name `UCS`. Active low signals are asserted when driven to a low logic level and deasserted when driven to a logic high level. The second memory device also has 18 address signal terminals MA0-MA17, and contains the portion of the operating system software residing in the lowermost portion of the memory address space. Terminals MA0-MA17 of the second memory device are also connected to address signal terminals A0-A17 of the microcontroller, and the second memory device is enabled by a programmed lower chip select signal (LCS#). The third memory device has 19 address terminals MA0-MA18 and is allocated for applications programs. Terminals MA0-MA18 of the third memory device are connected to address signal terminals A0-A18 of the microcontroller, and the third memory device is enabled by a programmed middle chip select signal (MCS#). The CSU asserts signal UCS# when address values 786,432 (C0000h) through 1,048,575 (FFFFFh) are driven upon the address signal terminals, asserts signal LCS# when address values 0 (00000h) through 262,143 (3FFFFh) are driven upon the address signal terminals, and asserts signal MCS# when address values 262,144 (40000h) through 786,431 (BFFFFh) are driven upon the address signal terminals.
Application programs tend to grow larger with time as new functions are added. In addition, each hardware support function incorporated within a microcontroller typically requires additional instructions for configuration and operation. At the same time, software compatibility requires that the number of address lines and the method of address signal generation remain the same. As a result, increasing the amount of memory accessible by a microcontroller is a problem often requiring unique solutions.
One common solution has been to replace a "smaller" memory device with a "larger" memory devices having a greater number of memory locations and requiring additional address signals. The microcontroller coupled to the larger memory devices generates additional control signals which function as the additional address signals. Special software is used to generate the additional control signals. The additional control signals typically form the most significant address signals, dividing the larger memory device into multiple sections or "banks" of memory. All of the memory banks created in this fashion have the same number of memory locations (i.e., are the same size). The additional control signals select between the available memory banks, determining which of the memory banks is active.
For example, the third memory device in the above example may be replaced by a 1024K×8 memory device having 20 address signal terminals MA0-MA19. If terminals MA0-MA19 of the third memory device were connected to respective address signal terminals A0-A19 of the microcontroller, the portions of the third memory device which overlap the uppermost and lowermost portions of the memory address space (i.e., half the memory locations within the third memory device) would not be accessible as the MCS# signal would not be asserted during memory accesses involving these portions. However, by connecting terminals MA0-MA18 of the third memory device to respective address signal terminals A0-A18 of the microcontroller and connecting an additional control signal generated by the microcontroller to terminal MA19, the microcontroller may access all of the memory locations within the third memory device. This configuration creates two separate memory banks within the third memory device, each memory bank containing 512K memory locations. Special software executed by the microcontroller is used to generate the additional control signal, thereby selecting between the two memory banks.
The requirement of the x86 architecture to reserve portions of the memory address space creates problems when adding memory devices with capacities which exceed the available chip select ranges and contain memory locations with addresses within (i.e., mapped to) reserved portions of the memory address space. In this case, any of the memory banks mapped to a reserved portion of the memory address space may be active when the RESET signal is asserted or when an interrupt occurs. The most straightforward solution to this problem is also the least desirable: duplicate the applicable operating system software in each memory bank. The RESET signal assertion problem may be overcome by ensuring the additional control signals are driven to a logic high level (i.e., a logic 1) when the RESET signal is asserted. However, each memory bank mapped to the lowermost portion of the memory address space must contain a copy of the 1,024-byte interrupt vector table, and each memory bank mapped to the uppermost portion of the memory address space must include interrupt service routines which are either complete or include enough instructions to switch to a "common" memory bank containing the interrupt service routines.
For example, assume an x86-based microcontroller is coupled to two different memory devices: a first 256K×8 Flash memory device and a second 1,024×8 SRAM memory device. The first memory device has 18 address terminals MA0-MA17 and contains the portion of the operating system software residing in the uppermost portion of the memory address space. Terminals MA0-MA17 of the first memory device are connected to respective address signal terminals A0-A17 of the microcontroller, and the first memory device is enabled by a programmed upper chip select signal (UCS#). The second memory device has 20 address terminals MA0-MA19, and contains the portion of the operating system software residing in the lowermost portion of the memory address space. The remainder of the second memory device is available for application programs.
In order for the microcontroller to access all of the memory locations within the second memory device, terminals MA0-MA18 of the second memory device are connected to respective address signal terminals A0-A18 of the microcontroller, the microcontroller generates an additional control signal connected to terminal MA19, and the second memory device is enabled by a programmed lower chip select signal (LCS#). The CSU asserts signal UCS# when address values 786,432 (C0000h) through 1,048,575 (FFFFFh) are driven upon the address signal terminals, and asserts signal LCS# when address values 0 (00000h) through 524,287 (7FFFFh) are driven upon the address signal terminals. The second memory device contains two memory banks each containing 512K memory locations mapped between address values 0 (00000h) and 524,287 (7FFFFh). Special software executed by the microcontroller generates the additional control signal, thereby selecting between the two memory banks. However, as a result of the requirement of the x86 architecture to reserve portions of the memory address space, both memory banks must contain a copy of the 1,024-byte interrupt vector table in memory locations corresponding to address values 0 (00000h) through 1,023 (003FFh).
It would be beneficial to have a microcontroller which includes additional hardware to generate additional "auxiliary" address signals. When address signals are generated which correspond to an address within a portion of the memory address space reserved for operating system software, the additional hardware would produce auxiliary address signals such that a single memory bank containing the operating system software is always accessed. Such a microcontroller would eliminate the need to duplicate operating system software in each memory bank mapped to a reserved portion of the memory address space, allowing efficient utilization of larger memory devices. Furthermore, software compatibility with previous microcontroller products would be advantageously maintained.
SUMMARY OF THE INVENTION
The problems outlined above are in large part solved by a microcontroller which includes additional hardware which generates multiple auxiliary address signals needed to expand the memory address space of the microcontroller. The auxiliary address signals allow access to memory locations within external memory devices which would not otherwise be accessible while advantageously maintaining software compatibility with previous microcontroller products. The auxiliary address signals form the most significant bits of augmented addresses, thereby dividing memory locations within the external memory devices into multiple memory banks of equal size. When memory banking is enabled, software instructions select the desired memory bank by writing appropriate values to address bit positions within a memory banking control (MBC) register. The auxiliary address signals are normally produced having values stored within corresponding bit positions of the MBC register. When address signals are generated which correspond to a portion of the memory address space reserved for operating system software, however, the additional hardware modifies the auxiliary address signals such that a selected memory bank is always accessed. As a result, operating system software need only be present in the selected memory bank. This method of generating the auxiliary address signals eliminates the need to duplicate operating system software in each memory bank mapped to a reserved portion of the memory address space, allowing efficient utilization of the external memory devices.
The microcontroller includes an execution unit, a bus interface unit (BIU), and a chip select unit (CSU) all coupled to signal lines of a core bus. The execution unit is configured to execute microprocessor instructions, preferably instructions from an x86 instruction set. The BIU includes multiple data buffers and handles all data transfer operations between the microcontroller and one or more external devices coupled to the microcontroller (e.g., memory devices and I/O devices) in accordance with established protocols. During the execution of microprocessor instructions, the execution unit generates output data which represent offset portions of addresses of memory locations from which data is to be read or to which data is to be written. The BIU receives the offset portion of the address via the core bus and combines the offset portion with a segment portion in order to produce multiple address signals corresponding to the address. The CSU receives the BIU address signals via the core bus and uses the BIU address signals to generate several different chip select signals. Each chip select signal is associated with a programmable range of addresses. The CSU asserts a chip select signal when the BIU address signals define an address within the corresponding range of addresses.
The microcontroller also includes an auxiliary address generator (AAG) which generates the auxiliary address signals. The auxiliary address signals are used along with the BIU address signals to access memory locations within one or more external memory devices. Each added auxiliary address signal doubles the number of memory locations which may be accessed within an external memory device using the BIU address signals alone. The auxiliary address signals are used to select a memory bank, and the BIU address signals are used to access the memory locations within the selected memory bank. A subset of the auxiliary address signals may be associated with the uppermost portion of the memory address space, and the remaining auxiliary address signals are associated with the lowermost portion of the memory address space.
When memory banking is enabled, the AAG produces the auxiliary address signals having values stored within corresponding address bit positions of the MBC register. When address signals are generated which correspond to a portion of the memory address space reserved for operating system software, however, the AAG ignores the address bit positions within the MBC register and produces auxiliary address signals having predetermined values. As a result, a selected memory bank within an external memory device is always accessed when address signals are generated which correspond to a portion of the memory address space reserved for operating system software.
The CSU generates two chip select signals associated with an uppermost portion of the memory address space of the microcontroller: UCS0# and UCS1#. Chip select signal UCS1# is terminated at an I/O pad and is used to enable an external memory device. Chip select signal UCS0# is routed to the AAG. The CSU asserts chip select signal UCS0# when an address within the uppermost portion of the memory address space reserved for operating system software is generated. The AAG uses chip select signal UCS0# to generate the auxiliary address signals associated with the uppermost portion of the memory address space. For example, when memory banking is enabled and chip select signal UCS0# is asserted, the AAG ignores the address bits within the MBC register and produces the auxiliary address bits associated with the uppermost portion of the memory address space with predetermined values. For example, when memory banking is enabled and chip select signal UCS0# is asserted, the AAG may produce the auxiliary address bits associated with the uppermost portion of the memory address space with values of 1. As a result, only a selected memory bank within an external memory device is accessed when an address within the uppermost portion of the memory address space reserved for operating system software is generated by the BIU.
The CSU also generates two chip select signals associated with a lowermost portion of the memory address space of the microcontroller: LCS0# and LCS1#. Chip select signal LCS1# is terminated at an I/O pad and is used to enable an external memory device. Chip select signal LCS0# is routed to the AAG. The CSU asserts chip select signal LCS0# when an address within the lowermost portion of the memory address space reserved for operating system software is generated. The AAG uses chip select signal LCS0# to generate the auxiliary address signals associated with the lowermost portion of the memory address space. For example, when memory banking is enabled and chip select signal LCS0# is asserted, the AAG ignores the address bits within the MBC register and produces the auxiliary address bits associated with the lowermost portion of the memory address space with predetermined values. For example, when memory banking is enabled and chip select signal LCS0# is asserted, the AAG may produce the auxiliary address bits associated with the lowermost portion of the memory address space with values of 0. As a result, only a selected memory bank within an external memory device is accessed when an address within the lowermost portion of the memory address space reserved for operating system software is generated by the BIU.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1 is a block diagram of a preferred embodiment of a microcontroller of the present invention, wherein the microcontroller includes an execution unit, a bus interface unit (BIU), a chip select unit (CSU), a memory banking control (MBC) register, and an auxiliary address generator (AAG);
FIG. 2 is a block diagram of a preferred embodiment of a UMCS0 register within the CSU, wherein the UMCS0 register includes a block size field for storing address range information relating to an uppermost portion of the microcontroller memory address space reserved for operating system software;
FIG. 3 is a block diagram of a preferred embodiment of a UMCS1 register within the CSU, wherein the UMCS1 register includes a block size field for storing address range information relating to memory locations within an external memory device coupled to the microcontroller and mapped to the uppermost portion of the microcontroller memory address space;
FIG. 4 is a block diagram of a preferred embodiment of an LMCS0 register of the CSU, wherein the LMCS0 register includes a block size field for storing address range information relating to a lowermost portion of the microcontroller memory address space reserved for operating system software;
FIG. 5 is a block diagram of a preferred embodiment of an LMCS1 register within the CSU, wherein the LMCS1 register includes a block size field for storing address range information relating to memory locations within an external memory device coupled to the microcontroller and mapped to the lowermost portion of the microcontroller memory address space;
FIG. 6 is a block diagram of a preferred embodiment of the MBC register of FIG. 1, wherein the MBC register includes multiple bit positions for storing desired auxiliary address signal values;
FIG. 7 is a block diagram of a computer system including the microcontroller of FIG. 1 coupled to a first and second external memory devices, wherein two auxiliary address signals AA0 and AA1 allow access to all memory locations within the first external memory device, and wherein two auxiliary address signals AA2 and AA3 allow access to all memory locations within the second external memory device;
FIG. 8 is a block diagram of a memory map of the first memory device of FIG. 7, wherein the auxiliary address signals AA0 and AA1 divide the memory locations within the first memory device into four memory banks 0-3 each having an equal number of memory locations, and wherein only a reserved portion of memory bank 3 is accessed when an address within the uppermost portion of the memory address space reserved for operating system software is generated; and
FIG. 9 is a block diagram of a memory map of the second memory device of FIG. 7, wherein the auxiliary address signals AA2 and AA3 divide the memory locations within the second memory device into four memory banks 0-3 each having an equal number of memory locations, and wherein only a reserved portion of memory bank 0 is accessed when an address within the lowermost portion of the memory address space reserved for operating system software is generated.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram of a preferred embodiment of a microcontroller 10 of the present invention. Microcontroller 10 includes an execution unit 12, a bus interface unit (BIU) 14, a chip select unit (CSU) 16, a memory banking control (MBC) register 18, an auxiliary address generator (AAG) 20, a core bus 22, a first set of I/O pads 24, a first I/O pad 26, a second I/O pad 28, and a second set of I/O pads 30, all formed upon a single monolithic semiconductor substrate (i.e., chip). Execution unit 12 executes microprocessor instructions, preferably from an instruction set of an x86 microprocessor. BIU 14 includes multiple data buffers and performs data transfer operations between microcontroller 10 and external devices coupled to microcontroller 10 (e.g., memory devices and I/O devices) in accordance with established protocols. BIU 14 generates m address signals A0-Am-1 during data transfer operations. CSU 16 uses the address signals generated by BIU 14 to generate chip select signals which enable external memory devices during data transfer operations. Core bus 22 includes multiple signal lines. Execution unit 12, BIU 14, and CSU 16 are coupled to core bus 22 and communicate with one another via signals driven upon the signal lines of core bus 22.
During manufacture of microcontroller 10, signal lines to be connected to external devices are terminated at flat metal contact regions (i.e., I/O pads) located upon an exposed surface of the chip. Following manufacture, microcontroller 10 is typically secured within a protective semiconductor device package. Each I/O pad is then connected to a terminal (i.e., pin) of the device package by a signal line (i.e., a wire).
During the execution of microprocessor instructions, execution unit 12 generates output data which represent offset portions of addresses of memory locations from which data is to be read or to which data is to be written. BIU 14 receives the offset portion of the address, combines it with a segment portion, and produces address signals A0-Am-1. The segment portion is typically stored in one of several segment registers within the BIU. Each address signal A0-Am-1 is driven upon a corresponding member of the first set of I/O pads 24. The simultaneous values of address signals A0-Am-1 determine an address of a memory location within an external memory device, and all possible combinations of simultaneous values of address signals A0-Am-1 determine the memory address space of microprocessor 10.
BIU 14 also drives address signals A0-Am-1 upon signals lines of core bus 22. CSU 16 receives address signals A0-Am-1 via core bus 22 and uses the address signals to generate several different chip select signals. Each chip select signal is associated with a programmable range of addresses. CSU 16 asserts a chip select signal when address signals A0-Am-1 define an address within the corresponding range of addresses.
CSU 16 includes an upper memory chip select 0 (UMCS0) register 32, an upper memory chip select 1 (UMCS1) register 34, a lower memory chip select 0 (LMCS0) register 36, and a lower memory chip select 1 (LMCS1) register 38. UMCSO register 32, UMCS1 register 34, LMCS0 register 36, and LMCS1 register 38 are programmable registers, meaning software instructions may change the contents of any one of these registers by writing a value to an address associated with the target register. CSU 16 uses address range information stored within UMCS0 register 32 to generate an active low upper memory chip select 0 (UCS0#) signal, address range information stored within UMCS1 register 34 to generate an active low upper memory chip select 1 (UCS1#) signal, address range information stored within LMCS0 register 36 to generate an active low lower memory chip select 0 (LCS0#) signal, and address range information stored within LMCS1 register 38 to generate an active low lower memory chip select 1 (LCS1#) signal. Chip select signals UCS1# and LCS1# are driven upon respective first I/O pad 26 and second I/O pad 28.
Address range information stored within UMCS0 register 32 defines an uppermost portion of the memory address space reserved for operating system software, and address range information stored within LMCS0 register 36 defines a lowermost portion of the memory address space reserved for operating system software. CSU 16 thus asserts signal UCS0# when address signals A0-Am-1 correspond to an address within the uppermost portion of the memory address space reserved for operating system software. Similarly, CSU 16 asserts signal LCS0# when address signals A0-Am-1 correspond to an address within the lowermost portion of the memory address space reserved for operating system software.
AAG 20 uses chip select signals UCS0# and LCS0# along with the contents of MBC register 18 to produce n auxiliary address signals AA0-AAn-1, where n≧2. MBC register 18 includes bit positions for storing desired values of corresponding auxiliary address signals (i.e., 0 or 1). Each auxiliary address signal AA0-AAn-1 is driven upon a corresponding member of the second set of I/O pads 30. Auxiliary address signals AA0-AAn-1 are added to address signals A0-Am-1 generated by BIU 14 to form augmented addresses within augmented memory address spaces. Each added auxiliary address signal doubles the number of memory locations which may be accesses using address signals A0-Am-1 alone. One or more auxiliary address signals are used to form the most significant bits of an augmented address. Auxiliary address signals AA0-AAn-1 divide memory locations within an external memory device receiving the address signals into multiple memory banks having equal numbers of memory locations (i.e., of equal size), and address signals A0-Am-1 are used to access the memory locations within each memory bank.
AAG 20 generates auxiliary address signals AA0-AAn-1 such that when BIU 14 generates address signals A0-Am-1 corresponding to a portion of the memory address space reserved for operating system software, the augmented address accesses only one of the multiple memory banks. AAG 20 thus eliminates the need to duplicate operating system software in each memory bank mapped to a portion of the memory address space reserved for operating system software, allowing larger memory devices having a greater number of memory locations to be used efficiently.
FIG. 2 is a block diagram of a preferred embodiment of UMCS0 register 32. UMCS0 register 32 includes a block size field 40 occupying three contiguous bit positions of UMCS0 register 32. Block size field 40 defines a portion of the memory address space of microcontroller 10 extending from the highest address value (i.e., all address signals A0-Am-1 having a value of 1) down to a lower boundary defined by the size of a memory block. Table 1 below shows preferred block size field 40 encoding information for a microcontroller generating 20 address signals A0-A19 and having a corresponding 1 Mbyte memory address space.
TABLE 1______________________________________UMCS0 Block Size Field Programming Values.Block Size Memory CorrespondingField Contents Block Size Lower Boundary______________________________________000 512K 80000h001 -- (Reserved) --010 -- (Reserved) --011 -- (Reserved) --100 256K C0000h101 -- (Reserved) --110 168K E0000h111 64K F0000h______________________________________
FIG. 3 is a block diagram of a preferred embodiment of UMCS1 register 34. UMCS1 register 34 includes a block size field 42 occupying three contiguous bit positions of UMCS1 register 34. Block size field 42 defines a portion of the memory address space of microcontroller 10 extending from the highest address value (i.e., all address signals A0-Am-1 having a value of 1) down to a lower boundary defined by the size of a memory block. The portion of the address space defined by block size field 42 must be greater than or equal to the portion of the address space defined by block size field 40 of UMCS0 register 32. Table 2 below shows preferred block size field 42 encoding information for a microcontroller generating 20 address signals A0-A19 and having a corresponding 1 Mbyte memory address space.
TABLE 2______________________________________UMCS1 Block Size Field Programming Values.Block Size Memory CorrespondingField Contents Block Size Lower Boundary______________________________________000 512K 80000h001 -- (Reserved) --010 -- (Reserved) --011 -- (Reserved) --100 256K C0000h101 -- (Reserved) --110 168K E0000h111 64K F0000h______________________________________
FIG. 4 is a block diagram of a preferred embodiment of LMCS0 register 36. LMCS0 register 36 includes a block size field 44 occupying three contiguous bit positions of LMCS0 register 36. Block size field 44 defines a portion of the memory address space of microcontroller 10 extending from the lowest address value (i.e., all address signals A0 -Am-1 having a value of 0) to an upper boundary defined by the size of a memory block. Block size field 44 preferably contains encoded information relating the memory block size as shown in Table 3 below.
TABLE 3______________________________________LMCS0 Block Size Field Programming Values.Block Size Memory CorrespondingField Contents Block Size Upper Boundary______________________________________000 64K 0FFFFh001 168K 1FFFFh010 -- (Reserved) --011 256K 3FFFFh100 -- (Reserved) --101 -- (Reserved) --110 -- (Reserved) --111 512K 7FFFFh______________________________________
FIG. 5 is a block diagram of a preferred embodiment of LMCS1 register 38. LMCS1 register 38 includes a block size field 46 occupying three contiguous bit positions of LMCS0 register 38. Block size field 46 defines a portion of the memory address space of microcontroller 10 extending from the lowest address value (i.e., all address signals A0 -Am-1 having a value of 0) to an upper boundary defined by the size of a memory block. The portion of the address space defined by block size field 46 must be greater than or equal to the portion of the address space defined by block size field 44 of LMCS0 register 36. Block size field 46 preferably contains encoded information relating the memory block size as shown in Table 4 below.
TABLE 4______________________________________LMCS1 Block Size Field Programming Values.Block Size Memory CorrespondingField Contents Block Size Upper Boundary______________________________________000 64K 0FFFFh001 168K 1FFFFh010 -- (Reserved) --011 256K 3FFFFh100 -- (Reserved) --101 -- (Reserved) --110 -- (Reserved) --111 512K 7FFFFh______________________________________
FIG. 6 is a block diagram of a preferred embodiment of MBC register 18. MBC register 18 is programmable, and includes a single banking enable (BE) bit 48, a mode field 50 occupying three contiguous bit positions, and four address bits AB0-AB3 (labeled 52) corresponding to four respective auxiliary address signals AA0-AA3. Memory banking is enabled when BE bit 48 is a 1, and is disabled when BE bit 48 is a 0. AB0-AB3 contain the values of AA0-AA3 to be generated, thus defining a memory bank to be accessed as described above. The contents of the three bit positions of mode field 50 determine whether AB0-AB3 apply to a memory device mapped to the uppermost portion (U) or the lowermost portion (L) of the memory address space of microprocessor 10 per Table 5 below.
TABLE 5______________________________________MBC Register Mode Field Programming Values.Mode Applies To MemoryField Device Mapped To:Contents AB0 AB1 AB2 AB3______________________________________000 U U U U001 U U U L010 U U L L011 U L L L100 L L L L101 -- -- -- --110 -- -- -- --111 -- -- -- --______________________________________
When memory banking is enabled and chip select signals UCS0# and LCS0# are deasserted, AAG 20 produces AA0-AA3 with the values stored within bits AB0-AB3 (labeled 52) of MBC register 18. Software instructions executed by execution unit 12 select desired memory banks within external memory devices coupled to microprocessor 10 by storing appropriate values within bits AB0-AB3 (labeled 52) of MBC register 18. When address signals A0-Am-1 indicating an address within the uppermost portion of the memory address space reserved for operating system software are generated by BIU 14, CSU 16 asserts chip select signal UCS0#. When chip select signal UCS0# is asserted, AAG 20 ignores the contents of bits AB0-AB3 (labeled 52) of MBC register 18 and produces the subset of auxiliary address bits AA0-AA3 associated with the uppermost portion of the memory address space with predetermined values. For example, when memory banking is enabled and chip select signal UCS0# is asserted, AAG 20 may produce the subset of auxiliary address bits AA0-AA3 associated with the uppermost portion of the memory address space with values of 1. As a result, operating system software need only reside within one of the memory banks mapped to the uppermost portion of the memory address space, and the corresponding portions of all other memory banks mapped to the uppermost portion of the memory address space are thus made available for application programs.
When an address within the lowermost portion of the memory address space reserved for operating system software is generated by BIU 14, CSU 16 asserts chip select signal LCS0#. When memory banking is enabled and chip select signal LCS0# is asserted, AAG 20 ignores the contents of bits AB0-AB3 (labeled 52) of MBC register 18 and produces the subset of address bits AA0-AA3 associated with the lowermost portion of the memory address space with predetermined values. For example, when memory banking is enabled and chip select signal LCS0# is asserted, AAG 20 may produce the subset of auxiliary address bits AA0-AA3 associated with the lowermost portion of the memory address space with values of 0. As a result, operating system software need only reside within one of the memory banks mapped to the lowermost portion of the memory address space, and the corresponding portions of all other memory banks mapped to the lowermost portion of the memory address space are thus made available for application programs.
It is noted that microcontroller 10 may include a direct memory access (DMA) unit having multiple DMA channels, each DMA channel being capable of transferring data between two different address ranges within the memory address space of microcontroller 10 without involving execution unit 12. In this case, microcontroller 10 preferably includes additional memory banking registers similar to MBC register 18 to facilitate DMA data transfer operations. AAG 20 selects between the multiple memory banking registers, using values stored within one of the multiple memory banking registers to produce AA0-AA3 when memory banking is enabled and chip select signals UCS0# and LCS0# are deasserted.
FIG. 7 will now be used to further describe microcontroller 10 by way of an illustrative example application. FIG. 7 is a block diagram of a computer system 54 including microcontroller 10. Microcontroller 10 is coupled to a first memory device 56 and a second memory device 58. Memory device 56 may be, for example, a 1024×8 Flash memory device having 20 address terminals MA0-MA19 and a chip enable terminal CE#. Memory device 58 may be, for example, a 1024×8 SRAM memory device also having 20 address terminals MA0-MA19 and a chip enable terminal CE#. Microcontroller 10 generates 20 address signals A0-A19, but only the first 18 address signals A0-A17 are used. Memory device 56 is mapped to the uppermost 512K portion of the 1 Mbyte memory address space of microcontroller 10 by the contents of UMCS1 register 34. Memory device 58 is mapped to the lowermost 512K portion of the 1 Mbyte memory address space of microcontroller 10 by the contents of LMCS1 register 38. Address terminals MA0-MA17 of both memory device 56 and memory device 58 are coupled to respective address signals A0-A17 generated by microcontroller 10. Chip enable terminal CE# of memory device 56 is coupled to chip select signal UCS1# generated by microcontroller 10, and chip enable terminal CE# of memory device 58 is coupled to chip select signal LCS1# generated by microcontroller 10. Auxiliary address signals AA0 and AA1 generated by microcontroller 10 are mapped to the uppermost portion of the address space by the contents of MBC register 18 and are coupled to address terminals MA18 and MA19, respectively, of memory device 56. Auxiliary address signals AA2 and AA3 generated by microcontroller 10 are mapped to the lowermost portion of the address space by the contents of MBC register 18 and coupled to address terminals MA18 and MA19, respectively, of memory device 58. Memory devices 56 and 58 also include data terminals MD0-MD7 (not shown) respectively coupled to data signals D0-D7 (not shown) of microcontroller 10.
FIG. 8 is a block diagram of a memory map of first memory device 56. FIG. 8 illustrates how auxiliary address signals AA0 and AA1, generated by AAG 20, divide the memory locations within memory device 56 into four memory banks 0-3 each containing 256K memory locations. The memory locations within each memory bank are mapped to the uppermost portion of the memory address space of microcontroller 10 and accessible using the 18 address signals A0-A17. Software instructions executed by execution unit 12 select the desired memory bank by storing values within bits AB0-AB1 of MBC register 18 according to Table 6 below.
TABLE 6______________________________________Values of AA0 and AA1 and Selected Memory Bank.AA0 AA1 Memory Bank Selected______________________________________0 0 Bank 00 1 Bank 11 0 Bank 21 1 Bank 3______________________________________
When an address within the uppermost portion of the memory address space reserved for operating system software is generated by BIU 14, CSU 16 asserts chip select signal UCS0#. Upon receiving the asserted UCS0# signal, AAG 20 ignores the contents of AB0 and AB1 within MBC register 18 and produces AA0 and AA1 with values of 1. Thus reserved portion 60 of bank 3 of memory device 56 is always accessed when an address within the uppermost portion of the memory address space is generated by BIU 14, regardless of the contents of AB0 and AB1 within MBC register 18. As a result, operating system software residing within bank 3 need not be duplicated within banks 0-2, freeing up the corresponding portions of banks 0-2 for applications programs.
FIG. 9 is a block diagram of a memory map of second memory device 58. FIG. 9 illustrates how auxiliary address signals AA2 and AA3, also generated by AAG 20, divide up the augmented address space associated with memory device 58 into four memory banks 0-3 each containing 256K memory locations. The memory locations within each memory bank are mapped to the lowermost portion of the memory address space of microcontroller 10 and are accessible using the first 18 address signals A0-A17. Software instructions executed by execution unit 12 select the desired memory bank by storing values within bits AB2-AB3 of MBC register 18 according to Table 7 below.
TABLE 7______________________________________Values of AA2 and AA3 and Selected Memory Bank.AA2 AA3 Memory Bank Selected______________________________________0 0 Bank 00 1 Bank 11 0 Bank 21 1 Bank 3______________________________________
When an address within the lowermost portion of the memory address space reserved for operating system software is generated by BIU 14, CSU 16 asserts chip select signal LCS0# as described above. Upon receiving the asserted 1CSO# signal, AAG 20 ignores the contents of bits AB2 and AB3 within MBC register 18 and produces AA2 and AA3 with values of 0. Thus reserved portion 62 of bank 0 is always accessed when an address within the lowermost portion of the memory address space is generated by BIU 14, regardless of the contents of bits AB2 and AB3 within MBC register 18. As a result, operating system software residing within bank 0 need not be duplicated within banks 1-3 of memory device 58, freeing up the corresponding portions of banks 1-3 for applications programs.
It will be appreciated by those skilled in the art having the benefit of this disclosure that this invention is believed to be a microcontroller which includes additional hardware which generates multiple auxiliary address signals needed to expand the memory address space of the microcontroller. When an address is generated within a portion of the memory address space reserved for operating system software, the additional hardware produces the auxiliary address signals such that a selected memory bank is always accessed. Furthermore, it is also to be understood that the form of the invention shown and described is to be taken as exemplary, presently preferred embodiments. Various modifications and changes may be made without departing from the spirit and scope of the invention as set forth in the claims. It is intended that the following claims be interpreted to embrace all such modifications and changes. | A microcontroller is presented including additional hardware which generates multiple auxiliary address signals needed to expand the memory address space of the microcontroller. The auxiliary address signals allow access to memory locations within external memory devices which would not otherwise be accessible while advantageously maintaining software compatibility with previous microcontroller products. The auxiliary address signals form the most significant bits of augmented addresses, thereby dividing memory locations within the external memory devices into multiple memory banks of equal size. When memory banking is enabled, software instructions select the desired memory bank by writing appropriate values to address bit positions within a memory banking control (MBC) register. The auxiliary address signals are normally produced having values stored within corresponding bit positions of the MBC register. When address signals are generated which correspond to a portion of the memory address space reserved for operating system software, however, the additional hardware modifies the auxiliary address signals such that a selected memory bank is always accessed. As a result, operating system software need only be present in the selected memory bank. This method of generating the auxiliary address signals eliminates the need to duplicate operating system software in each memory bank mapped to a reserved portion of the memory address space, allowing efficient utilization of the external memory devices. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to an optical pick-up device, and more particularly, to an improved optical pick-up device for reading and/or writing information to and from a recording medium, in which a lens holder that holds a lens that focuses light onto a recording surface of the recording medium is movably supported by cantilever springs.
[0003] 2. Description of the Related Art
[0004] In for example CD-ROM or CD-RW disk drive units in which a rotating disk-like recording medium (hereinafter simply disk) is loaded, a laser beam is projected onto the disk and information is recorded (written) onto the disk or reproduced (read) from the disk. The optical pick-up device installed in such types of disk drive units includes, among other components, an object lens that directs a laser beam emitted from a laser diode onto the disk. The orientation of the object lens is adjusted so that the focus of the light directed onto the disk by the object lens coincides with a recording surface of the disk.
[0005] In other words, an optical pick-up device performs focus control and tracking control so that the object lens follows changes in the track due to eccentricities in the rotation of the disk and/or wobble due to rotation of the disk. This type of control of the object lens is performed by an actuator using an electromagnetic force, the actuator being typically composed of a combination of a coil and a magnet.
[0006] A lens holder that supports the object lens is made compact and lightweight in order to facilitate focus and tracking control, with four wire-like elastic supports (that is, cantilever springs) arranged in parallel forming a supporting structure that supports the lens holder and that moves minutely in either a focus direction or a tracking direction, as the case may be, by the driving force from the actuator.
[0007] Further, the lens holder is placed so as to be contained within a frame formed into the shape of the letter U, the open portion being at a proximal end. Base portions of the four wire-like elastic supports are joined to a suspension fixedly mounted on a distal end of the frame, with tip portions joined to the lateral surfaces of the lens holder. As a result, the lens holder is supported by the four wire-like elastic supports in such a way as to be movable in a direction parallel to the frame.
[0008] However, a drawback of the above-described conventional optical pick-up device is that, when installed in a laptop personal computer or other similar portable apparatus and such apparatus is dropped during handling, the movement of the lens holder caused by such an impact on the pick-up unit is greater than that which is normally imparted thereto, thus damaging the wire-like elastic supports.
[0009] It is possible to provide the lens holder with lateral projections protruding therefrom, so that the projections contact the frame so as to restrict the range of movement of the lens holder and thus prevent the lens holder from being damaged by excessive movement. However, if the center of gravity of the lens holder and the center drive point of the actuator diverge from each other, an angular moment comes into play around the projection after the projection contacts the frame, thus twisting or rotating the lens holder around the tip of the projection and thereby deforming the wire-like elastic supports.
[0010] With the disk drives installed in laptop personal computers in particular, in which a seek direction (that is, the tracking direction) of the optical pick-up is slanted at approximately a 45 degree angle with respect to a front panel of the disk holder (thus taking advantage of the additional length afforded by using a corner of the disk drive unit frame instead of a lateral side of the frame), the direction of the shock of impact upon dropping the laptop (assuming the laptop is dropped on the front panel of the disk holder) and the direction of drive of the actuator are at approximately a 45 degree angle with respect to each other. In short, the structure easily allows an angular moment to be generated about the tip of the projection of the lens holder, thereby deforming the wire-like elastic supports.
[0011] If the wire-like elastic supports are thus deformed, then the positioning and angle of the lens can change and information can no longer be written to or read from the disk.
[0012] It is possible to use relatively thick wire for the wire-like elastic supports so as to prevent the wire-like elastic supports from being deformed by the shock of impact. However, the thicker the wire the more rigid the wire-like elastic support, which makes it more difficult to move the primary resonance frequency (at which focus control and tracking control low-frequency sensitivity tends to deteriorate) to a desired frequency.
[0013] In order to set the primary resonance frequency to a desired frequency and prevent focus control and tracking control low-frequency sensitivity from deteriorating, the longer the suspension the better. However, the conventional optical pick-up typically installed in an ordinary laptop computer, and particularly the recording pick-up, has a substantial number of mounted parts, thus limiting the space available to lengthen the suspension.
[0014] More specifically, there is limited space in which to accommodate the optical pick-up devices of the disk drive units typically installed in laptop computers. Optical pick-up devices of optical disk drive units that can record are becoming more common, but these, too, have the disadvantage of a large number of component parts as compared to the read-only type of optical pick-up device, thus placing additional constraints on the already limited amount of space available for installation. For both these reasons, the wire-like elastic supports can be neither lengthened nor thickened. Additionally, thickening the wire-like elastic supports reduces their sensitivity, which is undesirable.
SUMMARY OF THE INVENTION
[0015] Accordingly, it is an object of the present invention to provide an improved and useful optical pickup device, in which the above-described disadvantage is eliminated.
[0016] The above-described object of the present invention is achieved by an optical pick-up device comprising a lens that focuses light onto a recording medium; a lens holder that holds the lens; a suspension that supports the lens holder disposed opposite a distal end of the lens holder; a frame formed so as to be disposed opposite both lateral surfaces of the lens holder and the distal end of the lens holder, the frame supporting the suspension; a plurality of elastic supports that movably support the lens holder, a distal end of the elastic supports mounted on the suspension and a proximal end retained by the lens holder; and an actuator that drives the lens holder, the actuator including a focus coil, a tracking coil and at least one magnet, the optical pick-up device having a plurality of projections provided on at least one of the lens holder, the frame and the suspension, the projections acting as stoppers that restrict a rotation of the lens holder so as to prevent excessive deformation of the elastic supports.
[0017] According to this one aspect of the invention, excessive displacement of the lens holder due to impact can be prevented and a rotational moment prevented from acting on the lens holder, thus making it possible to prevent deformation of the cantilever springs and to prevent deterioration in the accuracy of the focus control and tracking control of the lens holder due to the impact of an external shock to the optical pick-up device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These and other objects, features, aspects and advantages of the present invention will become better understood and more apparent from the following description, appended claims and accompanying drawings, in which:
[0019] [0019]FIG. 1 is a perspective view of an optical pickup device according to one embodiment of the present invention;
[0020] [0020]FIG. 2 is a plan view of an optical pick-up device according to one embodiment of the present invention;
[0021] [0021]FIG. 3 is a lateral cross-sectional view of an optical pick-up device according to one embodiment of the present invention;
[0022] [0022]FIG. 4 is a perspective exploded view of a movable part and a yoke base that supports the movable part;
[0023] [0023]FIG. 5 is a plan view showing a case in which an impact acts in a direction B on an optical pick-up device according to the present invention;
[0024] [0024]FIG. 6 is a perspective view of a disk drive unit;
[0025] [0025]FIG. 7 is a plan view of a disk drive unit;
[0026] [0026]FIG. 8 is a plan view of a disk drive unit with the tray extended;
[0027] [0027]FIG. 9 is a plan view of a disk drive, a double-headed arrow showing a direction of movement of the optical pick-up device;
[0028] [0028]FIG. 10 shows a load acting on an optical pickup device according to the present invention when the disk device has been dropped;
[0029] [0029]FIG. 11 is a schematic diagram showing a direction of effect of a rotational moment in the event of an impact acting in directions H, I on a lens holder center of gravity G;
[0030] [0030]FIG. 12 is a schematic diagram showing a direction of effect of a rotational moment in the event of an impact acting in directions J, K on a lens holder center of gravity G; and
[0031] [0031]FIG. 13 is a plan view of an optical pick-up device according to one variation of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] A detailed description will now be given of an improved optical pick-up device according to the present invention, with reference to the accompanying drawings. It should be noted that identical or corresponding elements are given identical or corresponding reference numbers in all drawings, with detailed descriptions thereof given once and thereafter omitted.
[0033] [0033]FIG. 1 is a perspective view of an optical pickup device according to one embodiment of the present invention. FIG. 2 is a plan view of an optical pick-up device according to one embodiment of the present invention. FIG. 3 is a lateral cross-sectional view of an optical pick-up device according to one embodiment of the present invention. FIG. 4 is a perspective exploded view of a movable part and a yoke base that supports the movable part.
[0034] As shown in FIGS. 1 - 4 , an optical pick-up device 10 comprises an object lens 12 , a lens holder 14 that holds the object lens 12 , a yoke base 15 (hereinafter frame 15 ) that supports the lens holder 14 , a focus coil 16 mounted on the lens holder 14 and a tracking coil 18 mounted on the lens holder 14 , a pair of magnets 30 , 32 , a yoke 22 integrally mounted on the frame 15 that supports the pair of magnets 30 , 32 , a suspension holder 24 fixedly mounted on the frame 15 and that supports four wire-like elastic supports—in actuality cantilever springs— 26 a , 26 b , 26 c and 26 d positioned between the frame 15 and the lens holder 14 . The lens holder 14 is thus supported by the four cantilever springs 26 a - 26 d so as to be movable in a horizontal tracking direction (that is, a direction indicated by arrow A-B) as well as in a vertical focusing direction (a direction indicated by arrow C-D), the four cantilever springs 26 a - 26 d being arranged in parallel The focus coil 16 is an actuator for driving the object lens 12 in a vertical direction. The tracking coil 18 is an actuator for driving the object lens 12 in the horizontal direction. The yoke 22 , which has a pair of U-shaped arms 22 a , 22 b bent so as to extend vertically, is fixedly mounted on a floor plate 15 c disposed between a pair of arms 15 a , 15 b extending horizontally from the frame 15 . The magnet 30 is mounted on one arm 22 a of the yoke 22 so as to pass through an interior of the focus coil 16 . The magnet 32 is mounted on the other arm 22 b of the yoke 22 , opposite the tracking coil 18 .
[0035] A first set of projections 37 a , 37 b project laterally from lateral surfaces of a proximal end of the lens holder 14 . A second set of projections 38 a , 38 b project laterally from an intermediate position on the lateral surfaces of the lens holder 14 . Finally, a third set of projections 39 a , 39 b project from the suspension holder 24 toward a distal end 14 c of the lens holder 14 .
[0036] The first set of projections 37 a , 37 b are shorter than the second set of projections 38 a , 38 b by approximately 1 to 2 mm, so when the lens holder 14 swings the second set of projections 38 a , 38 b contacts an inner surfaces of the arms 15 a , 15 b of the frame 15 first, after which the first set of projections 37 a , 37 b then contacts the inner surfaces of the arms 15 a , 15 b so as to restrict a rotation of the lens holder.
[0037] Additionally, as noted previously, the distal end 14 c of the lens holder 14 opposes the third set of projections 39 a , 39 b , thus restricting a rotation of the lens holder 14 in a direction opposite the direction or rotation restricted by the first set of projections 37 a , 37 b when the distal end 14 c of the lens holder 14 contacts the third set of projections 39 a , 39 b.
[0038] Accordingly, the contacting of the first set of projections 37 a , 37 b and the second set of projections 38 a , 38 b against the inner surfaces of the arms 15 a , 15 b of the frame 15 prevents a rotational moment from acting on the cantilever springs 26 a - 26 d , thereby preventing the cantilever springs 26 a - 26 d from being deformed by an excessive force and preventing a deterioration in accuracy in the focus control or tracking control of the lens holder due to the impact of an external shock.
[0039] The suspension holder 24 is fixedly mounted on a mounting part 15 d of the frame 15 together with a printed circuit board 34 by a screw 36 . A base portion of the cantilever springs 26 a - 26 d , which are positioned so as to extend in a horizontal direction, penetrates the printed circuit board 34 . A proximal tip (that is, a free end) of the cantilever springs 26 a - 26 d passes above and below the second set of projections 38 a , 38 b . Additionally, silicon gel adhesives 40 for elastically mounting the cantilever springs 26 a - 26 d are adhered to a proximal surface of the suspension holder 24 . The adhesive 40 is gelled by ultraviolet radiation so as to provide the cantilever springs 26 a - 26 d with a viscous damping effect with respect to movement of the lens holder 14 in a focus direction and movement of the lens holder 14 in a tracking direction.
[0040] Additionally, ends of the focus coil 16 and the tracking coil 18 are connected to relay substrates 42 , 44 through which the free ends of the cantilever springs 26 a - 26 d pass, with an electrical current being supplied to the focus coil 16 and the tracking coil 18 via the cantilever springs 26 a - 26 d.
[0041] It should be noted that a movable part 46 subject to focus control and tracking control comprises the above-described object lens 12 , lens holder 14 , focus coil 16 , tracking coil 18 , and coil relay substrates 42 , 44 .
[0042] The object lens 12 supported by the lens holder 14 is adjusted to a position at which an electromagnetic force generated by the passing of current through the focus coil 16 and the tracking coil 18 is balanced with a magnetic force arising between the pair of magnets 30 , 32 .
[0043] A more detailed description will now be given of the structure of the lens holder 14 .
[0044] The lens holder 14 has a lens holder part 14 a and a coil holder part 14 b that extends distally toward the suspension holder 24 from the lens holder part 14 a and supports the focus coil 16 and the tracking coil 18 .
[0045] As shown in FIG. 3, a laser beam (indicated by an arrow) emitted from a laser diode 28 is reflected by a reflecting mirror 50 toward the object lens 12 , where it is focused onto a disk 12 disposed opposite to and above the object lens 12 . The pair of magnets 30 , 32 are disposed opposite the U-shaped mounting arms 22 a , 22 b of the yoke 22 , and opposite the focus coil 16 and tracking coil 18 provided on the lens holder 14 . As noted previously, the lens holder 14 is movably supported by the four cantilever springs 26 a - 26 d that extend horizontally.
[0046] [0046]FIG. 5 is a plan view showing a case in which an impact acts in a direction B on an optical pick-up device according to the present invention.
[0047] As shown in FIG. 5, in a case in which the optical pick-up 10 is subjected to an impact force F acting in the direction indicated as B in the drawing, the lens holder 14 supported by the four cantilever springs 26 a - 26 d moves in the B direction and the second projection 38 a projecting from the lateral surface of the lens holder 14 contacts the inner surface of the arm 15 a of the frame 15 , after which the first projection 37 a projecting from the lateral surface of the lens holder 14 contacts the inner surface of the arm 15 a of the frame 15 . As a result, a counter-clockwise rotation of the lens holder 14 is stopped by the first projection 37 a and the second projection 38 a coming into contact with the inner surface of the arm 15 a . Additionally, after the second projection 38 a contacts the inner surface of the arm 15 a , the third projection 39 a extending proximally from the suspension holder 24 toward a distal end 14 c of the lens holder 14 keeps the lens holder 14 from rotating in a clockwise direction.
[0048] Thus, damage to the cantilever springs 26 a - 26 d can be prevented even in the event of an external shock to the unit because the first set of projections 37 a , 37 b , the second set of projections 38 a , 38 b and the third set of projections 39 a , 39 b function as stoppers that restrict the rotation of the lens holder 14 .
[0049] A description will now be given of the above-described optical pick-up device 10 installed in a typical CD-ROM drive unit.
[0050] [0050]FIG. 6 is a perspective view of a disk drive unit. FIG. 7 is a plan view of a disk drive unit. FIG. 8 is a plan view of a disk drive unit with the tray extended.
[0051] As shown in FIG. 6, a disk drive unit 61 is for example a CD-ROM drive unit installed in a laptop-type personal computer, and includes a top cover (for ease of description not shown in the diagram), a bottom cover 66 , with a turntable 68 rotatably supported by a tray 70 in a space created between the top cover and the bottom cover 66 . At a center of the turntable 68 there is a clamp mechanism 73 for engaging a disk 52 at an inner periphery of the disk 52 so as to clamp the disk 52 firmly onto the turntable 68 . A disk container 74 having a diameter larger than that of the disk 52 is disposed around an outer periphery of the turntable 68 .
[0052] The optical pick-up device 10 for reading information recorded on the disk 52 clamped to the turntable by the clamping mechanism 73 of the turntable 68 is mounted below the disk container 74 so as to be movable in a direction of a radius of the disk 52 (hereinafter radial direction of the disk). The optical pick-up device 10 is contained in a concavity 74 a of the disk container 74 . A pick-up cover 78 having an opening 78 a that is as large as the range of movement of the object lens 12 of the optical pick-up device 10 covers the concavity 74 a.
[0053] The opening 78 a in the pick-up cover 78 extends in a direction that is at a diagonal, that is, an angle of approximately 45 degrees with respect to the tray 70 , that is, the direction indicated by an arrow Xa-Xb. The optical pick-up device 10 is also movable along the opening 78 a in the pick-up cover 78 in the same diagonal direction.
[0054] An eject button 82 is provided on a center of a front bezel 80 joined to a proximal edge the tray 70 .
[0055] When a disk motor 69 provided beneath the turntable 68 is activated, thus rotating the turntable 68 and the disk 52 clamped onto the turntable 68 by the clamping mechanism 73 , the air at the center of the rotation is moved to the outer periphery of the disk by the centrifugal force of rotation.
[0056] As shown in FIG. 8, the tray 70 is supported by guide rails 90 , 92 along both sides thereof so that the tray 70 is slidable in the proximal and distal directions. When the eject button 82 provided on the front bezel 80 is pressed, the tray 70 lock is released and the released tray 70 is slid manually in the direction shown as Xa in FIGS. 7 and 8 to a point at which the disk may be replaced. After the disk 52 has been clamped onto the turntable 68 of the tray 70 , the tray 70 is then pushed manually back in the direction shown as Xb in FIGS. 7 and 8 until locked in a disk loaded position shown in FIG. 7.
[0057] A description will now be given of a pick-up drive mechanism 84 that moves the optical pick-up device 10 in a radial direction of the disk.
[0058] As shown in FIGS. 7 and 8, the pick-up drive mechanism 84 comprises a pair of guide shafts 85 , 86 that guide the optical pick-up device 10 in a diagonal direction indicated by the dashed lines in FIG. 7, a drive motor 87 that drives the optical pick-up device 10 , and a transmission mechanism 88 that transmits the rotational drive force of the drive motor 87 to the optical pick-up device 10 . Bearings 76 a , 76 b and 76 c project from both lateral surfaces of the optical pick-up device 10 and are fitted to the guide shafts 85 , 86 , such that the optical pick-up device is guided by the guide shafts 85 , 86 . The transmission mechanism 88 comprises a gear assembly 88 a that reduces the rotation of the drive motor 87 and a lead screw 88 b that is rotatably driven via the gear assembly 88 a . The optical pick-up device 10 has an engaging part 76 d that engages the threads of the lead screw 88 b.
[0059] A description will now be given of a movement operation of the optical pick-up device.
[0060] [0060]FIG. 9 is a plan view of a disk drive, a double-headed arrow showing a direction of movement of the optical pick-up device.
[0061] As shown in FIG. 9, the optical pick-up device 10 is moved along the diagonal of the tray 70 by the transmission of the rotation of the drive motor 87 to the lead screw 88 b via the gear assembly 88 a.
[0062] [0062]FIG. 10 shows a load acting on an optical pickup device according to the present invention when the disk device has been dropped.
[0063] As shown in FIG. 10, when the disk drive unit 61 is dropped on the front bezel 80 , a force F acts in a direction E on the optical pick-up device because the optical pick-up device 10 is designed to move along the diagonal of the tray 70 . In such a case, the force of impact F acts on the optical pick-up device 10 at an angle of approximately 45 degrees with respect to the direction in which the four cantilever springs 26 a - 26 d extend. Additionally, because the force of impact F acts downward with respect to the center of gravity G of the lens holder 14 , a rotational moment M is generated about the center of gravity G.
[0064] As a result, the lens holder 14 , supported as it is by the four cantilever springs 26 a - 26 d , moves in the direction E in which the force of impact F acts. Initially the second projection 38 a contacts the inner surface of the arm 15 a of the frame 15 , and then the third projection 39 a contacts the distal end 14 c of the lens holder 14 so that the lens holder 14 does not rotate in the clockwise direction (see FIG. 5).
[0065] Accordingly, even when the disk drive unit 61 is dropped a rotational moment due to the force of impact F does not affect the lens holder 14 and thus damage to the four cantilever springs 26 a - 26 d can be prevented.
[0066] [0066]FIG. 11 is a schematic diagram showing a direction of effect of a rotational moment in the event of a force of impact acting in directions H, I on a lens holder center of gravity G.
[0067] As shown in FIG. 11, in the case of a force of impact operating in directions H, I on the lens holder 14 center of gravity G, the rotational moment M acts in the H′, I′ directions. However, a rotation of the lens holder 14 is prevented by the first set of projections 37 a , 37 b projected from the proximal end of the lens holder 14 and the second set of projections 38 a , 38 b contacting the inner surfaces of the arms 15 a , 15 b of the frame 15 . Accordingly, a rotation moment M in the H′, I′ directions is prevented by the first set of projections 37 a , 37 b and the second set of projections 38 a , 38 b.
[0068] [0068]FIG. 12 is a schematic diagram showing a direction of effect of a rotational moment in the event of a force of impact acting in directions J, K on a lens holder center of gravity G.
[0069] As shown in FIG. 12, in the case of a force of impact operating in directions J, K on the lens holder 14 center of gravity G, the rotational moment M acts in the J′, K′ directions. However, a rotation of the lens holder 14 is prevented by the second set of projections 38 a , 38 b projected from the lateral surfaces of the lens holder 14 contacting the inner surfaces of the arms 15 a , 15 b of the frame 15 and by the third set of projections 39 a , 39 b provided on the suspension holder 24 contacting the distal end 14 c of the lens holder 14 . Accordingly, a rotation moment M in the J′, K′ directions is prevented by the second set of projections 38 a , 38 b and the third set of projections 39 a , 39 b.
[0070] As can be appreciated by those of ordinary skill in the art, although the present invention has been described with reference to embodiments in which projections functioning as stoppers are provided on the lateral surfaces of the lens holder 14 and on the suspension holder 24 , the present invention is not limited to such embodiments but includes also configurations in which, for example, projections that prevent a rotation of the lens holder 14 are provided on the lateral surfaces of the frame 15 , as shown in FIG. 13. FIG. 13 is a plan view of an optical pick-up device according to one variation of the present invention.
[0071] The above description is provided in order to enable any person skilled in the art to make and use the invention and sets forth the best mode contemplated by the inventors of carrying out the invention.
[0072] The present invention is not limited to the specifically disclosed embodiments, and variations and modifications may be made without departing from the scope and spirit of the present invention.
[0073] The present application is based on Japanese Priority Application No. 2000-377692 filed on Dec. 12, 2000, the entire contents of which are hereby incorporated by reference. | An optical pick-up device includes a lens that focuses light onto a recording medium, a lens holder that holds the lens, a suspension holder that supports the lens holder disposed opposite a distal end of the lens holder, a frame formed so as to be disposed opposite both lateral surfaces of the lens holder and the distal end of the lens holder, the frame supporting the suspension holder, a plurality of elastic supports that movably support the lens holder, a distal end of the elastic supports mounted on the suspension holder, and an actuator that drives the lens holder, wherein a plurality of projections is provided on at least one of the lens holder, the frame and the suspension holder, the projections acting as stoppers that restrict a rotation of the lens holder so as to prevent excessive deformation of the elastic supports. | 6 |
FIELD OF THE INVENTION
The invention relates to a manually operated apparatus or tool such as, for example, a drilling or holing apparatus, of the power hammer type, or a fastening apparatus of the sealing apparatus type having a piston propelled by gas.
BACKGROUND OF THE INVENTION
Such apparatuses may have operating and control electronics, an igniter plug, a fan, an electric motor or other components requiring an electrical power supply. Being manually operated and self-contained, they also comprise a power supply battery.
Once the battery has been mounted on the outside of the collection of the other elements of the apparatus, with the disadvantage, in particular, of exposing them to knocks which may damage them, a proposal was made to arrange them in an accommodating housing inside the apparatus, formed, for example, in a leg connected to the central body of the apparatus and running parallel to its operating handle.
As a safety measure, it was then proposed for the battery to be fixed in the apparatus by means of a double-action locking device, it being possible first of all for the battery to be locked mechanically and electrically and then disconnected electrically from the remainder of the apparatus while remaining mechanically connected thereto so as to prevent the operator from letting it fall out through not paying sufficient attention. Document EP 1 205 282 teaches such a device comprising, on the apparatus, a double trigger for actuating two retaining fingers designed to collaborate in succession with a single retaining catch formed on the battery. However, such an arrangement does not set aside the risk of the operator inadvertently actuating the double trigger twice and thus completely releasing the battery from the apparatus.
SUMMARY OF THE INVENTION
The present invention is aimed at reducing such a risk.
To this end, the invention relates first of all to an electric hand tool comprising, in a casing, electrically operated components and a housing to accommodate a battery that powers the said components, with detachable means of securing the battery in its housing in a position of mechanical locking and electrical connection to the said components and in a position in which it is mechanically retained in its housing but electrically disconnected, characterized in that the securing means are designed to retain the battery in the electrically disconnected position only by friction.
By virtue of the invention, in order to completely release the battery from the tool, an operator is obliged to take it in his hand and remove it from its housing, overcoming the friction forces which retain it, thus avoiding any risk of an unintentional wrong move.
In the preferred embodiment of the tool of the invention, the battery-accommodating housing is designed to accommodate therein a battery by sliding, and the battery securing means comprise an electrical locking finger and a mechanical retaining finger both mounted so that they can move, in a direction roughly orthogonal to the direction in which the battery slides, between a lock and a retaining position, respectively, and a retracted position.
As a preference, the locking and retaining fingers are mounted so that they can be moved into the retracted position against the action of elastic return means.
Advantageously, the locking finger is secured to a rod mounted to slide into the retracted position against the action of a return spring under the action of an actuating trigger and the retaining finger is secured to a pivoting elastic leaf.
Advantageously too, the locking finger and the retaining finger are mounted to be moved into the retracted position, one in each of two opposite directions.
The invention also relates to a battery for powering electrically operated components for the electric hand tool of the invention, characterized in that it comprises a mechanical and electrical locking catch and mechanical retaining ramp means.
In the preferred embodiment of the battery, the locking catch is formed by an undercut internal shoulder and the ramp means comprise a retaining boss with an entry ramp and an opposite retaining ramp advantageously formed near the entry end of the battery, via which end it is introduced into its accommodating housing in the tool, the locking catch and the retaining boss being formed respectively on two opposite sides of the battery.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood with the aid of the following description of the preferred embodiments of the tool and of the battery of the invention, with reference to the attached FIGURE depicting them in section, but, for clarity, with no hatching.
DETAILED DESCRIPTION OF THE INVENTION
The tool depicted in the FIGURE in this instance is a hammer drill intended to strike a drill bit, also driven in terms of rotation in support material, via a piston propelled in a cylinder, along an axis 1 , under the action of an electric motor powered by a battery 3 arranged in an accommodating housing 4 formed in a leg 5 , running roughly orthogonal to the axis 1 and connected to the casing 2 .
Also connected to the casing is an elbowed operating handle 6 , with a leg portion 7 roughly parallel to the leg housing the battery 5 and a portion 8 , for connection to the accommodating leg 5 , running roughly parallel to the axis 1 .
Housed in a housing 13 in the connecting portion of the handle 8 is a mechanical and electrical locking rod 9 running roughly parallel to the axis 1 . In its continuation, on the side facing towards the battery housing 4 , the rod 9 bears a locking finger 10 .
The locking rod 9 also bears, laterally, an actuating trigger 11 projecting from the handle 6 through an aperture 14 , on the inside 12 , between the two portions 7 , 8 and a return finger 15 , running parallel to the rod 9 , onto which there is slipped a return spring 16 bearing against the end wall 17 of the housing 13 and against a shoulder 18 formed by the finger 15 . The locking finger 10 is shaped to exhibit a passage ramp 19 inclined towards the axis 1 from the rear 20 towards the front 21 of the tool, for the passage of the battery 3 as it slides into its housing 4 .
In the rest position, which is the locked position, the locking finger 10 is returned by the spring 16 projecting into the battery housing 4 . The rod 9 is moved into a position of retraction of the finger 10 against the action of the spring 16 . In the battery accommodating leg 5 , on the anterior side which is the opposite end to the operating handle 6 , and therefore to the rod and to the locking finger, and near the casing 2 , there is fixed, via one end 23 , an elastic leaf 22 , bearing a boss 24 at its free end forming a retaining finger facing towards the battery accommodating housing 4 . The leaf 22 runs roughly orthogonally to the axis 1 , but its free portion is, however, inclined backwards so as to be able to pivot about its fixed end 23 and so that the retaining finger 24 can move roughly parallel to the axis 1 , between a rest position, which is a locked position, in which it projects into the battery housing 4 , and a retracted position, in its tool housing 38 , against the elasticity of the leaf.
As far as the battery 3 is concerned, this battery being of roughly parallelepipedal overall shape, near its entry end face 25 , it has, on its two opposed lateral sides 26 , 27 , two passage ramps 28 , 29 for respectively negotiating the mechanical retaining finger 24 and the mechanical and electrical locking finger 10 . A slight recess or hollow 30 is formed slightly beyond the ramp 28 , exhibiting a ramp 31 inclined in the opposite direction to the ramp 28 to form, on the one hand, a boss 32 for the mechanical retention of the battery and, on the other hand, a housing 30 for accommodating the retaining finger 24 in the rest position. Here, the housing 30 is delimited not only by the ramp 31 but by another ramp 33 inclined in the opposite direction and situated at a distance away from the entry face 25 that is at least equal to the length of the leaf 22 considered in the direction in which the battery is introduced. Closer to its rear end face 34 , on the side 27 of the battery, there is a locking catch 35 comprising an undercut internal shoulder 36 , facing away from the entry face 25 , and in this instance a ramp 37 inclined like the passage ramp 19 of the locking finger 10 .
The fitting and removal of the battery 3 in the tool will now be explained.
Offering the battery 3 up via its entry face 25 , it is introduced into the housing 4 . It is pushed thereinto in the direction of the arrow 39 , roughly orthogonal to the axis 1 . The ramp 29 , collaborating with the ramp 19 of the locking finger 10 , retracts it into its housing 13 , against the action of the spring 16 . The battery continues to be pushed, the locking finger 10 sliding along the side 27 of the battery until the ramp 28 , collaborating with the retaining finger 24 , retracts it in its turn into its tool housing 38 against the elasticity of the leaf 22 , then until the retaining finger 24 , having passed the boss 32 , and through elastic relaxation of the leaf 22 , returns to the battery housing 30 .
In this position, the battery is not yet electrically connected, but is mechanically retained in the tool in that, in order to extract it, it would be necessary to pull on it to overcome the friction force needed for the boss 32 to move past the retaining finger 24 .
It will be noted that, because of the height or extent of the battery housing 30 , the battery can still move to some extent, without the electrical connection ever being made inadvertently.
By continuing to push the battery 3 into its housing 4 , it can be truly clipped in, that is to say mechanically and electrically locked, when the retaining catch 35 comes opposite the retaining finger 10 which, under the action of the spring 16 , is returned by sliding into the catch.
Conversely, to remove the battery 3 from its housing 4 , the trigger 11 is actuated against the action of the spring 16 to disengage the finger 10 from the catch 35 then the battery is pulled to electrically disconnect the electrical components of the tool. It still, however, remains mechanically secured to the tool, as long as the boss 32 has not been moved past the retaining finger 24 . It is only by forcing this boss past the finger 24 and overcoming the corresponding friction forces that the battery can be fully removed from the tool. | The tool has, in a casing ( 2 ), electrically operated components and a housing ( 4 ) to accommodate a battery ( 3 ) that powers the components, with detachable elements ( 10, 24 ) of securing the battery in its housing in a position of mechanical locking and electrical connection to the components and in a position in which it is mechanically retained in its housing but electrically disconnected. The securing element ( 24 ) is designed to retrain the battery ( 3 ) in the electrically disconnected position only by friction ( 24, 31 ), thus avoiding any wrong move. | 1 |
FIELD OF THE INVENTION
The present invention relates to a method of setting molding conditions which is applied for the case where an injection molding machine is brought into run, using a mold with no data concerning its specification.
DESCRIPTION OF THE RELEVANT ART
Generally, the molding conditions to be set for an injection molding machine ranges over a wide variety, and since respective molding conditions affect each other, the process of setting certain molding conditions for an injection molding machine requires considerable skill and experience, thus constituting a specialty job.
Therefore, so far, some methods and techniques for automating the process of setting molding conditions so that even unskilled and unexperienced operators could perform the setting precisely and with ease have been proposed.
For example, a method is disclosed in Japanese Patent Application Laid-Open No. 2 (1990)-98419, wherein by considering the data of an injection molding machine, the material data of the plastic used, the shape and other features of a product to be injection-molded, initial molding conditions are selected, while some defects conceivable with the product to be molded and causes attributable to each defect and countermeasures for such defects are stored to solve the defects based on those data.
Another method is disclosed in Japanese Patent Application Laid-Open No. 4 (1992)-201314, wherein a data table which stores various molding conditions and another data table which stores the priority of countermeasures concerning respective state of molding based on the knowhow of experienced operators, with the aim of rendering optimum the molded product conditions, are prepared, whereby molding conditions are changed according to these data tables and the consequences of test injection molding until a molded product with acceptable quality is available.
Further another method is disclosed in Japanese Patent Application Laid-Open No. 5 (1993)-169507, wherein from the data base of quality product molding conditions which has been prepared by accumulating the data of molding conditions of molded products with acceptable quality, the optimal molding conditions for the intended products are extracted or in case similar products are not available, setting rules of default are provided to set the initial conditions, and necessary molding conditions are set performing test injection based on the above.
Meanwhile, these conventional methods presuppose the availability of mold data relative to the in-mold cavity volume, etc. or the shape of molded product. Therefore, in such a case like the above, regarding measured values, etc., test molding can be performed by setting molding conditions somewhat provisional, as initial conditions.
However, when manufacturing products, if the manufacturer thereof has within his plant or shop the entire production process including mold designing, he is allowed to know the mold data relative to a cavity volume, and so forth by referring to a mold drawing, or a mold model, etc. But for those makers having only a production line, when they are entrusted with the manufacture of molded products there are many cases where they receive only a set of molds from their clients being therefore deprived of mold data.
When the mold data are not available, it is necessary for the operator to empirically or by intuition, set the initial molding conditions concerning injection speed, injection pressure, etc. through visual examination of the mold cavity, etc. and then, performing the molding by setting measured values somewhat below the actual figures and increasing gradually said values while observing state of filling of the molded product, necessitating to set the molding conditions on trial and error basis by repeating trial molding. The result is that the number of operators capable to perform such setting is limited and because even skilled operators cannot undertake such molding conditional setting easily, the setting, consumed long hours, lowered productivity, and increased production cost in addition to the waste of material and energy. Further, due to mistaken or incorrect setting, when measured value or injection pressure is set in excess, there is a fear that designating a right setpoint of each molding conditional is set in excess, there is a fear that the mold interior is applied with abnormal pressure and the molds may possibly be damaged.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method of setting molding conditions for an injection molding machine, allowing even an unskilled operator to undertake the setting of molding conditions with great ease and without fail for such an injection molding machine loaded with a set of molds whose specifications' data are unclear, whereby the setting time may be shortened, productivity may be raised, production cost may be reduced, and the saving of material and energy may be realized.
Another object of the present invention is to provide a method of setting molding conditions for an injection molding machines, for preventing molds from being damaged and further to improve the safety thereof by eliminating improper setting.
To achieve each of these objects, in the present invention, when setting molding conditions for injection molding machine 1 using a set of molds whose specifications data are unclear, a method is utilized which comprises a first setting process A wherein, by inputting known data to controller 3, the molding conditions based on the data base prepawed in advance and said known data are set; a second setting process B wherein injection molding is performed according to previously set certain molding conditions with injection pressure P, injection speed V and screw 4 injection start position, while altering injection pressure P, based on the molded product and setting molding conditions regarding injection pressure P, injection speed V and measurement value Md, and a third setting process C wherein injection molding is carried out based on the molding conditions obtained from the second setting process B while said molding conditions are subsequently adjusted based on the outcomes of the check done for the product molded.
First setting process A includes a process to set the molding condition associated with temperature by way of inputting at least the data relative to the kind of material selected for injection molding as known data into controller 3.
Further in second setting process B, by setting, as certain molding conditions, injection pressure P to be one of lower pressure side Pd, injection speed V to be one of higher speed side Vh, and the injection start position of screw 4 is likewise selected at the rearmost retreat position Xb, to perform injection molding. And as a measure corresponding to filling defect of molded product, injection pressure P is boosted in order to obtain a magnitude of injection pressure P serving to provide quality products and subsequently, a correction value of pressure involved by the change of injection speed, is added to or subtracted from above-obtained injection pressure P to set the injection pressure thus obtained as one molding condition. In this case, injection pressure P is altered as much as a pre-selected amount of change depending on the degree of defective filling, followed by repetitive cycles of retest injection molding which is done at altered injection pressure P until quality molded products are available. The correction value of pressure is selected in response to the fluctuations of pressure variable depending on the override characteristic of a machine drive. Further in the second setting process B, average injection speed Va is obtained from screw's injection stroke Si at which the machine has provided quality molded products and from injection speed V fluctuating during the period of screw's injection stroke Si, and average injection speed Va thus obtained above is set as one molding condition. In this case, the injection stroke Si is obtained in a way such when injection speed V (or injection pressure P) which produced quality products, falls below pre-selected setpoint Vs of speed (or setpoint Ps of pressure), namely after injection speed V (or injection pressure P) becomes below setpoint Vs of speed (or above setpoint Ps of pressure), injection finish position Xf after the lapse of pre-selected time Ts is detected, whereby injection stroke Si is calculated from the difference between screw's injection finish position Xf detected and rearmost retreat position Xb thereof. In addition, screw' injection stroke Si (=Xb-Xf) is calculated from the difference between injection finish position Xf and rearmost retreat position Xb, while measurement Md is calculated by adding cushion stroke Sc set in advance to set the measurement Md thus obtained as a molding condition.
In the meanwhile, third setting process C includes an adjusting process to adjust injection speed V or injection pressure P in the injection process to multi-steps injection speed or pressure. The adjusting process serves to change injection speed V or injection pressure P, among pre-selected different filling processes of a filling process which has generated defective filling; or, to be more precise, at this stage, injection speed V or injection pressure P is altered as much as the pre-selected amount of change, followed by repetitive remolding cycles until defective filling is eliminated.
As is clear from above, the present invention divides the setting process of molding conditions into a plurality of processes to perform setting step-by-step. First, in the setting process A, by inputting known data into input controller 3, molding conditions based on the data base prepared in advance and said entered known data are set. In this setting process, inputting known data into the controller alone automatically selects necessary molding conditions. For example, when known data concerning the kind of material selected for injection molding is inputted into controller 3 as a known data, the molding conditions concerning temperature (barrel cylinder temperature, mold temperature, etc.) are selected, based on the data, relative to the physical property and characteristic of a molding material, which have been prepared in advance as a data base. With first setting process A completed, injection molding machine is ready to start for basic run.
Next, in the second setting process B, certain provisional molding conditions relative to injection speed, injection pressure, and injection start position of screw 4 are selected; namely, the setting is performed by setting the injection pressure at one pressure value on the lower pressure side Pd, the injection speed likewise at one speed value Vh, on the higher pressure side, and the injection start position of screw 4 set at the rearmost retreat position Xb, respectively, to carry out injection molding under the above prescribed molding conditions. The product molded is visually examined, and injection pressure P is altered, according to the procedure in second setting process B referred to above while at the same time, the molding conditions relative to injection pressure P, injection speed V and measurement Md are selected. In this case, if the operator can judge the degree of defective filling, molding conditional setting can be done semi-automatically. With second setting process B completed, injection molding machine 1 can produce molded products with reasonably improved quality.
Subsequently, in the third setting process C, injection molding is performed according to the molding conditions obtained from the second setting process B, and molding conditions are adjusted based on the molded product obtained. In this case, the third setting process includes an adjusting process to adjust injection speed V or injection pressure P in the injection process in multi-steps speed or pressure and if the operator can locate the position of defective filling and judge the degree of this failure, the setting of mold condition can be effected semi-automatically. In the third setting process C, adjustment of mold condition is implemented in a manner that the best quality molded products may be provided in, wherein a qualitative final decision regarding quality is made.
Thus, even an unskilled operator is allowed to easily undertake setting of mold condition without fail for injection molding machine 1, using a set of molds 2 whose specifications data are unclear while, semi-automatic setting of mold condition can be realized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart showing the sequence of mold conditions setting according to the method to which the present invention relates.
FIG. 2 is a block diagram illustrating the constitution of the injection molding machine to which the method of the present invention is applicable.
FIGS. 3(a) and 3(b) are typical sections of the heating cylinder, showing the screw position when performing the second setting process according to the method of the present invention.
FIG. 4 is a characteristic illustrative graph to describe the procedure of setting mold condition in the second setting process according to the method of the present invention.
FIG. 5 is an illustrative graph of injection speed characteristic to describe the procedure of injection speed setting in the second setting process according to the method of the present invention.
FIG. 6 is an override characteristic diagram of a hydraulic oil pump to describe the procedure of injection speed setting in the second setting procedure according to the method of the present invention.
FIG. 7 is a flowchart showing the setting sequence of molding condition in the second setting process according to the method of the present invention.
FIG. 8 is a flowchart showing the setting sequence of initial mold condition in the second setting process according to the method of the present invention.
FIG. 9 is a flowchart showing the sequence of changing the injection pressure in the second setting process according to the method of the present invention.
FIG. 10 is a principle illustrative diagram to describe how to change the injection pressure in the second setting process according to the method of the present invention.
FIG. 11 is another principle illustrative diagram to describe the method of changing the injection pressure in the second setting process according to the method of the present invention.
FIG. 12 is a pattern diagram of the keyboard, an input unit which is used setting in the third setting process according to the method of the present invention.
FIGS. 13(a), 13(b) and 13(c) are injection speed setting characteristic diagrams to describe the third setting process according to the method of the present invention.
FIG. 14 is a principle illustrative diagram to describe how to change the injection speed in the third setting process according to the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Next, preferred embodiments of the present invention are described in detail hereunder with reference to the accompanying drawings.
First, referring to FIG. 2, a description is made of an approximate constitution of injection molding machine 1 to which the method of the present invention is applicable, which relates to this preferred embodiment.
Injection molding machine 1 includes base 5; injection unit 6 is mounted on one side of the top surface of base 5 while a mold 2 concealed by safety cover 7 and whose specifications data are unknown is installed on the other side. In this case, mold 2 is supported by a mold clamping unit (not shown), and injection unit 6 is moved back and forth by injection unit drive 8. Injection unit 6 includes heating cylinder 9 which is provided with injection nozzle 10 at the fore end, and hopper 11 at the rear end while heating cylinder 9 incorporates screw 4 (see FIG. 3). Meanwhile, at the rear end of heating cylinder 9, there is installed screw drive 12 which turns and moves back and forth screw 4. For screw drive 12, a motor drive type using a servo motor and a hydraulic drive type having a hydraulic circuit are known.
On the other hand, in the FIG. 2, 3 refers to a controller housed within said base 5, performing the entire control of injection molding machine 1. 13 denotes an input unit (keyboard) mounted on a side panel 5p of base 5 and coupled to controller 3. Both input unit 13 and controller 3 are furnished with respective functions for setting various molding conditions. 14 refers to screw position sensor which, for example, when the screw drive is of the motor drive type, a rotary encoder to detect the revolutions of a servo motor can be used while when said drive is of the hydraulic drive type, a linear scale, etc. are applicable which directly detect the screw position. Screw position sensor 14 is coupled directly to controller 3 while, said sensor is also connected to controller 3 via speed converter 15. Speed converter 15 has a function of converting into a screw speed signal of the screw by differentiating the screw position signal from screw position sensor 14.
Meanwhile, 16 stands for an injection pressure sensor; in case for example, the screw drive is of the motor drive type a load cell can be utilized, which detects the back pressure working at the rear end of screw 3, and when the screw drive is of the hydraulic drive type, a hydraulic pressure sensor, and so forth to detect the pressure of a hydraulic cylinder is usable. 17 stands for a display mounted on side panel 5p, which presents various information serving also as an auxiliary unit of said input unit 13. Controller 3 is coupled to system computer 18 by way of an optical or a radio communication cable system.
Next, referring to FIGS. 1 through 14, the method of setting molding condition to which the present invention relates is described.
FIG. 1 is a flowchart showing the total setting sequence of molding condition to which the present invention relates.
First, prior to the setting of molding condition, an automatic setting mode of molding condition is selected by pressing selector key Ks of input unit 13 (step 21). Then, the setting of molding conditions based on the first setting process A is performed. At first, using input unit 13 and display 17, the known data concerning kind of material, screw specifications, etc. are inputted (step 22). In the controller 3, there is stored a data base concerning characteristics of materials, specifications of injection molding machine performance, basic molding conditions, etc. Then, the molding conditions relative to temperatures and basic molding conditions such as maximum screw stroke, etc. are set in controller 3 according to the known data inputted and the data base stored in the controller memory (step 23). Meanwhile, the molding conditions regarding temperatures, namely heating cylinder and mold temperatures are automatically selected, following the kind of material selected for injection molding. When the first setting process A is over, the setting of molding conditions based on the second setting process B is performed (step 24).
Next, the setting sequence of the molding conditions in the second setting process B is described, referring to FIGS. 3 through 11. First, with reference to FIG. 7, initial molding conditions are set (step 31). The setting of initial molding conditions is done according to a flowchart given in FIG. 8.
At first, the injection speed as injection condition is set at one speed value Vh, on the higher speed side (step 51). In this case, Vh, a value on the higher speed side is in a zone of speed higher than the intermediate speed specified in the speed setting range of an injection molding machine to be used. Preferably, the injection speed over 90% of the maximum injection speed is selected. Further, the injection start position of screw 3 is set to rearmost retreat position Xb (step 52). In this case, rearmost retreat position Xb is not a complete retreat limit position but includes a further rearward optional position behind said position Xb, sufficient for unit measurement of plastic. Further, the injection pressure is set at one pressure value on the lower pressure side Pb, side (step 53). In this case, Pb, a value on the lower pressure side is in a zone of pressure lower than the intermediate point of the pressure setting range of this injection molding machine. Preferably, Pb is selected at the reading under 30% of the maximum injection pressure. In addition to the above settings when setting initial molding conditions, other necessary items such as holding pressure changeover position, back pressure, cooling time, screw turning speed, and so forth (step 54) are set.
Also, setpoint Vs of screw speed and setpoint Ts of time are selected to detect screw injection finish position Xf of 4. Said setpoint Vs of speed refers to a threshold of injection speed V to detect the end of plastic filling, which can be set at approximately a stationary state or several meters/sec. Setpoint Ts of time refers to a duration which is necessary for securing more reliable plastic filling. Ts can be set, for example, at approximately several seconds.
Next, the screw back pressure is turned off (0) to perform measuring (step 32). In this case, screw 4 is moved back to rearmost retreat position Xb as shown in FIG. 3(a). Then, when the semi-automatic setting mode of molding condition is selected, injection unit 6 (with injection nozzle 10) starts advancing (steps 33, 34). Pressing the nozzle touch switch starts the injection. In other words, screw 4 moves forward according to the selected initial molding conditions, followed by injecting molten plastic L into molds 2 (step 35). At this time, controller 3 monitors injection speed V at the time of filling obtained from the speed converter 15. As shown in FIG. 4, when molten plastic is in the middle of filling into mold 2, injection speed V is much higher than setpoint Vs of speed, and when the filling of molten plastic L has ended of injection speed V quickly lowers to less than setpoint Vs of speed. Therefore, in monitoring injection speed V, if injection speed V is found less than setpoint Vs of speed, the controller starts to count the setpoint Ts of time (steps 36, 37). And when the count reaches setpoint Ts of time, injection finish position Xf is monitored (steps 38, 39) thereat.
In this case, by setting setpoint Ps of pressure as a threshold, the controller may monitor injection pressure P obtained from injection pressure sensor 16. Namely, as already mentioned, when the molten plastic L is in the middle of filling into the mold 2, injection pressure P is much lower than setpoint Ps of pressure. Therefore, when the filling of molten plastic L has ended an abrupt increase of pressure to more than setpoint Ps of pressure will result. Accordingly, when injection pressure P reaches setpoint Ps of pressure, the injection finish position Xf can be detected likewise above.
Next, the injection pressure is altered (step 40). The step of altering the injection pressure is aimed primarily to boost the injection pressure (one injection pressure) selected previously at a value on the low pressure side up to an adequate value. The altering sequence of the injection pressure is illustrated in a flowchart of FIG. 9.
At this stage, first, the back pressure is turned on, and measuring is effected in a state given with back pressure, and subsequently, injection unit 6 (injection nozzle 10) is moved back, followed by opening dies 2 (steps 61, 62, 63). Then, the molded product just ejected from the machine is judged whether or not there exists a defective filling to gather necessary data such as wall thickness of the product, gate pressure and so on for example (step 64). With the data relative to the product's wall thickness and the gate pressure, the time required to cool the molds is calculated automatically.
Meanwhile, input unit 13 is provided with selector keys Kx, Ky, Kz (see FIG. 2) capable to select ranks (on the of kind and degree of defective filling) while plural magnitudes of change each corresponding to one of respective rank of defective filling are designated previously in controller 3 to alter the injection pressure in steps with a view to eliminate defective filling.
For example, when the defective filling is due to a short shot of molten plastic, as shown in FIG. 10, the degree of the short shot is classified into three ranks "heavy," "medium" and "slight," wherein for "heavy," the pressure change rate (magnitude of change) is selected at +20% in reference to the maximum injection pressure, for "medium", the pressure change rate at +10%, and for "slight," the pressure change rate at +5%. In this case, although the degrees of defective filling have been divided into three ranks of "heavy," "medium" and "slight" these ranks may be expressed digitally. In the case quoted above, as an amount of change, a pressure change rate is applied because normally, the injection pressure is set with a rate against the maximum injection pressure. Therefore, as a degree of a short shot, when the rank of "heavy" is selected a pressure change rate of +20% is selected, with the currently set injection pressure being added with 20% the maximum injection pressure. As in the foregoing, the magnitude of injection pressure change may be specified as an absolute quantity or a ratio. Further, the magnitude of injection pressure change may be calculated through addition, and subtraction, or division or multiplication therewith.
Further, in the case of overfilling, as shown in FIG. 11, the degree of overfilling is classified into three ranks "heavy", "medium" and "slight" likewise the above. When the degree of overfilling is "slight," a pressure change rate of -2% is selected while for "medium", a pressure change rate of -5% is chosen and for "heavy," a pressure change rate of -10% is selected respectively. As in the foregoing, the pressure change rate is selected incrementally in response to the larger degree of defective filling.
Therefore, when short shot stemming from insufficient filling is found by visual check of a molded product, the injection pressure is increased (steps 65, 66). Namely, if the degree of detected short shot is "heavy" for example, corresponding selector key Kx of input unit 13 may be pressed. Because the injection pressure is being set at one pressure value Pb, on the lower pressure side as the initial molding conditions in this case, if Pd has previously been selected at 20%, controller 3 adds 20% of the pressure change rate to the injection pressure 20%, altering injection pressure P to 40%. Thereafter, using the altered (increased) injection pressure, is resumed. Namely, a remolding cycle prescribed in the process comprising steps 34-40 in FIG. 7 and steps 61-64 in FIG. 9 is started (step 67). Thereafter when the product molded shows again a short shot, the injection pressure is further raised likewise above. For example, when the short shot is ranked "medium", the current injection pressure is boosted as much as 10% of the pressure change rate and remolding cycle is started. The respective pressure change rates are different from one another and are so selected as to correspond to larger degree of defective filling. Therefore, when repeating a remolding cycle after altering the injection pressure, selected ranks will become gradually lower, resulting finally in quality molded products (step 68).
Meanwhile, when there is a finding of defective filling, in the form of burr due to overfilling, a process to decrease injection pressure is performed (steps 69, 70). In this case, by judging the degree of overfilling, if the degree of overfilling is "slight," one of the selector keys of input unit 13 is pressed, whereby controller 3 subtract 2% of the pressure change rate from the current injection pressure. Subsequently, using the newly set (reduced) injection pressure, a remolding cycle is repeated until the machine becomes capable of producing quality molded products (steps 71, 72).
When quality molded products are finally available, controller 3 reads from screw position sensor 14 the then injection finish position Xf, and calculates not only the extent of injection stroke Si (S i =X b -X f ) from detected injection finish position Xf and rearmost retreat position Xb, but also the measurement Md by adding pre-selected cushion stroke Sc to said calculated injection stroke Si. Then, measurement Md just obtained is set in controller 3 as a molding condition (step 41).
Further, the molding conditions duly workable are obtained with injection pressure P and injection speed V designated which have finally produced quality molded products, and the molding conditions thus obtained are set in controller 3 (step 41). In this case, average injection speed Va prevailing during injection stroke Si and at which quality molded products become available is calculated. In other words, the injection speed V, due to initial molding conditions, is set at one speed Vh, a value on the higher speed side. However, as shown in FIG. 7, in the actual injection molding the injection speed becomes substantially smaller than designated injection pressure V. Therefore, average injection speed Va is calculated, which is then set into controller 3 as a molding condition. In this case, average injection speed Va may be obtained either by dividing the sum of respective injection speeds Vn sampled at prescribed short time intervals with the number of samplings or by calculating area of velocity characteristics in reference to a position of screw 4, with this calculated area being divided with the position.
On the other hand, injection pressure P is set by adding a pressure correction value. Meanwhile, injection speed V is set at in one speed value Vh, on the higher speed side due to initial molding conditions and is set after being averaged. Therefore, average injection speed Va is smaller than Vh, a value of injection speed selected in the setting of initial molding conditions. To stabilize average injection speed Va becoming smaller than initially selected injection speed Vh, a prescribed overdrive pressure is added to the injection pressure as a correction pressure taking into account the pressure fluctuations in response to override characteristic F of a proportional pump, etc. shown in FIG. 6, to set the average injection speed. With the above steps, the setting of molding conditions based on the second setting process B, is over.
Next, the setting of molding conditions based on the third setting process C, is performed (step 25). In the third setting process C, test injection molding is performed according to the molding conditions obtained through the second setting process B while said molding conditions are adjusted based on the products molded. The adjustment in this case is made, basically under the same principle as applied for injection pressure changing process described above. The difference is that in the former process, the injection pressure or the injection speed is set at one pressure, or speed value without being adjusted value, whereby it is difficult to totally eliminate a locally emerging defect of the molded product, with no alternative but to accept those molded products exhibiting a relatively most favorable state as quality products however, the adjustment undertaken in third setting process C is characterized by fine adjustment which is made, paying attention to the filling process in the cycle of injection, in unit of filling process to the molding conditions (injection speed or injection pressure) regarding altered one speed value injection speed or injection pressure of or one pressure value, to obtain best quality molded products. Therefore, to be more concrete, with said fine adjustment, in third setting process C, the injection speed is adjusted in multi-step, multi-speed and the injection pressure is adjusted in multi-steps multi-pressure.
Shown in FIG. 12 is a part of the keyboard provided for input unit 13, K1, K2, K3, . . . stand for a plurality of selector keys to select the kinds of defective fillings, K7, K8, K9 are other selector keys to specify the filling process during which the occurrence of defective filling has occurred. In case with the present preferred embodiment, the failures of filling are categorically specified, using respective selector keys: K1 to designate "burrs"; K2 "short shot"; K3 "sink (shrink) mark"; K4 "jetting"; K5 "crack"; and K6 "flow mark." In addition to these selector keys, the keyboard is further provided with the following selector keys to designate as filling processes, K7 to specify "runner"; K8 "midway of filling"; and K9 "last stage of filling." K0 is a selector key to specify the case wherein no failure occurred.
Further, for every king of defective filling, ranking corresponding to each of different degrees of defective filling and each amount of change corresponding to said ranking are set using input unit 13 and controller 3. In a manner that the respective amounts of change become larger corresponding to larger degree rankings. In this case, if the defective filling is a burr, for example, the extent of burrs is classified into respective ranking of "large", "medium" and "small." In the present embodiment, as shown in FIG. 12, Ka key corresponds to "large", Kb key to "medium" and Kc to "small." Further as illustrated in FIG. 14, for the case of "large" burrs, the speed change rate (amount of change) is selected at -10%, for "medium" burrs, said rate at -5%, and for "small burrs, said rate at -2% respectively. As a matter of course, the ranking of "large", "medium" and "small" may be expressed digitally. The present invention used the rate of speed change for the amount of change because, normally, the injection speed is set with a rate of maximum injection speed. Therefore, when "large" is selected, 10% is subtracted from the injection speed. In this way, the amount of change may be set either in absolute quantity or a percentage, or may be set by means of addition/subtraction or multiplication/division to the injection speed.
Also, controller 3 has a function of changing selected molding conditions of filling process with the amount of change corresponding to the kinds and rankings of selected defective filling.
Below, the sequence of adjustment process is described in detail. First, when molding is performed according to the molding conditions obtained through the second setting process B, a first molded product is obtained, and a visual check thereof is performed. In this case, if a burr caused by overfilling is found, for example, at a certain part of the molded product, when the operator judges the burr from its location that the burr was generated at the "last stage of filling" and assesses the burr to be in the rank of "large," it suffices that he presses selector keys K1, K9 and Ka, whereby in controller 3, the amount of change corresponding to the selected rank of "large" and which is equivalent to a speed change rate of -10% shown in FIG. 14 is selected, and the injection speed for the corresponding to that of filling process in the "last stage of filling" is decreased subsequently as much as 10%." In other words, assuming that one speed value of injection speed V, after being altered, was selected at 50% of the maximum injection speed, as shown in FIG. 13 (a), average injection speed Va for the filling process in the "last stage of filling" is altered to 40% as shown in FIG. 13 (b).
Then, injection molding is performed again with decreased injection speed Va, and when the product molded from said injection molding is found with burrs, the newly selected injection speed is further reduced. If the rank of burrs found with the molded product is appraised to fall into a lower rank of "medium", Kb key on the keyboard of input unit 13 is pressed, whereby in controller 3, the amount of change corresponding to the rank of "medium", namely, a speed change rate of -5% is selected, and injection speed Vb calculated by subtracting 5% is selected as shown in FIG. 13 (c). Therefore, injection molding, using the injection speed altered for the filling process in the "last stage of filling", may be repeated until burrs will disappear completely. In this case, the respective amounts of change provided for adjustment are different and are arranged in a gradual sequence in a manner that the larger the defective filling, the larger is the amount of change. Therefore, repeating remolding will gradually lower the ranks of defective filling, resulting eventually in a total elimination of burrs generating in the "last stage of filling".
It is preferred that, as shown in FIG. 12, display 17 presents the injection speed characteristic in reference to a screw position, and especially, the display is for double presentation of pre-adjustment injection speed characteristic Ea and post-adjustment injection speed characteristic Eb, whereby the display may provide auxiliary service to help the operator perform adjustment with more ease and reliability.
When the foregoing setting processes have been completed, adjustments such as reducing the injection molding cycle time, etc. are performed to set finally, the obtained molding conditions in the controller (step 26).
One preferred embodiment of the present invention has been described. It is however understood that the present invention is by no means limited only to this embodiment. In the above embodiment, one aspect of setting molding condition through injection speed adjustment is exemplified but molding condition setting is also applicable to injection pressure. The constitutional details, method, etc. of the present invention can be modified or altered optionally without deviating from the spirit and scope of the present invention. | A method of setting molding conditions for an injection molding machine 1 using a mold 2 whose specifications data are unclear included three setting processes. In the first setting process A, by inputting known data into controller 3, the molding conditions based on a data base prepared in advance and said input known data are set. In the second setting process B, injection molding is performed according to prescribed molding conditions pre-selected concerning injection pressure P, injection speed V and the injection start position of screw 4, and then, based on the product just molded, injection pressure P is altered, to set said altered injection pressure P, injection speed V and proper pre-feed measurement value Md as molding conditions. In the third setting process C, injection molding is performed according to molding conditions obtained from said second setting process B, and subsequently, taking into account the findings from the product just molded, said molding conditions are adjusted. In this manner, even an unskilled operator is allowed to undertake setting molding conditions reliably and with great ease for an injection molding machine loaded with a set of molds whose specifications data are unclear. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of provisional patent application serial No. 60/308,365 filed Jul. 27, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to methods and devices for providing a stress-relieving joint between a riser and the keel of a floating platform.
[0004] 2. Description of the Related Art
[0005] Deep water floating platforms use risers to communicate production fluid from the sea floor to the floating production platform. Floating platforms have a portion that lies below the surface of the sea. For stability of the platform, it is desired that there be a very deep draft. The spar, for example, is a popular style of floating platform that has an elongated, cylindrical hull portion which, when deployed, extends downwardly a significant distance into the sea. The lowest portion of the submerged hull is referred to as the keel. Currents in the sea tend to move the floating platform laterally across the sea surface. Despite the presence of anchorages, the platform imparts bending stresses to the riser during lateral movement. Localized, or point, stresses are particularly problematic for risers.
[0006] One known joint arrangement for use with risers and floating vessels is described in U.S. Pat. No. 5,683,205 issued to Halkyard. Halkyard describes an arrangement wherein a joint means is positioned within a keel opening in the floating vessel to reduce the amount of stress upon a pipe passing through the keel opening. The joint means consists of a radially enlarged sleeve member with an elastomeric annulus at either end that is in contact with both the sleeve member and the pipe. Halkyard's intent is to reduce stress upon the pipe that is imposed by lateral movement of the floating vessel upon the sea. In order to reduce stress, Halkyard contacts the pipe at two points with an elastomeric annulus, which is described as providing a resilient, somewhat yieldable connection. Unfortunately, Halkyard's arrangement is problematic since it permits almost no angular movement of the pipe within the sleeve member. While point stresses upon the pipe are reduced, they are still significant. Further, the pipe is required to bend within the confines of the sleeve. This bending, together with the induced point stresses at either end of the sleeve, place significant strain on the pipe.
[0007] The present invention addresses the problems in the prior art.
SUMMARY OF THE INVENTION
[0008] Keel joint assemblies are described that permit a degree of rotational movement of a riser within the keel of a floating vessel. The assemblies of the present invention greatly reduce the amount of stress and strain that is placed upon the riser, as well. The present invention describes keel joint assemblies that provide a limiting joint between the riser and the keel opening that permits some angular rotation of the riser with respect to the floating vessel. Additionally, the limiting joint permits the riser to move upwardly and downwardly within the keel opening, but centralizes the riser with respect to the keel opening so that the riser cannot move horizontally with respect to the keel opening.
[0009] In described embodiments, the limiting joint is provided by a single annular joint that allows that riser to move angularly with respect to the can. In some embodiments, the keel joint assembly incorporates a cylindrical stiffening can that radially surrounds a portion of the riser and is disposed within the keel opening. In these embodiments, a flexible joint is provided between the can and the riser. Supports or guides may be used to retain the can within the keel opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 illustrates an exemplary riser extending upwardly from the sea floor and through a spar-type floating platform.
[0011] [0011]FIG. 2 is a schematic side, cross-sectional view of a first exemplary keel joint assembly constructed in accordance with the present invention.
[0012] [0012]FIG. 3 is a schematic side, cross-sectional view of a second exemplary keel joint assembly constructed in accordance with the present invention.
[0013] [0013]FIG. 4 is a schematic side, cross-sectional view of a third exemplary keel joint assembly constructed in accordance with the present invention.
[0014] [0014]FIG. 5 is a schematic side, cross-sectional view of a fourth exemplary keel joint constructed in accordance with the present invention.
[0015] [0015]FIG. 6 is a schematic side, cross-sectional view of a fifth exemplary keel joint assembly constructed in accordance with the present invention.
[0016] [0016]FIG. 7 is a schematic side, cross-sectional view of a sixth exemplary keel joint assembly constructed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] [0017]FIG. 1 generally illustrates a subsea wellhead 10 that has been installed into the sea floor 12 . A riser 14 is connected to the wellhead 10 and extends upwardly through the waterline 16 to a floating platform 18 . The riser 14 is used to transmit production fluids or as a drilling conduit from the wellhead 10 to production facilities (not shown) on the floating platform 18 . The riser 14 is used to provide a closed conduit from the wellhead 10 to the floating platform 18 . The floating platform 18 shown is a spar-type floating vessel that carries production equipment (not shown) on an upper deck 20 . The hull 22 of the platform 18 is a cylinder having flotation chambers within and a central, vertically-oriented passage 24 through which the riser 14 is disposed. It is noted that the configuration for a passage used in floating platforms varies from platform to platform. Sometimes the passage is lined by a cylindrical wall that extends substantially the entire length of the hull. In other platforms, the passage is partially lined by such a wall, and in still other platforms, there is essentially no lining for the passage. The keel 26 is located at the lower end of the hull 22 . A keel joint, indicated generally at 28 , is used to permit axial upward and downward motion as well as angular deflection of the riser 14 with respect to the keel 26 . It is desired that the keel joint 28 be constructed to preclude localized bending stresses in the riser 14 that could damage it, resulting in structural failure of the riser 14 .
[0018] Referring to FIG. 2, there is shown a first, and currently most preferred, exemplary keel joint arrangement 30 that can be used as the keel joint 28 to support the riser 14 . The keel joint arrangement 30 includes a stiff cylindrical can 32 that radially surrounds a portion of the riser 14 . The can 32 is retained within and disposed away from the walls of the keel opening or passage 24 by supports or guides 34 that are securely affixed with the hull 22 . While there are only two upper and two lower supports 34 shown in FIG. 2, it should be understood that there are actually more such supports 34 , perhaps four or more upper and four or more lower supports 34 and that the supports are located to surround the circumference of the riser 14 . The supports 34 have rounded, non-puncturing ends 36 to contact the outer wall of the can 32 . It is noted that the supports 34 are not affixed to the can 32 , thereby permitting the can 32 to move upwardly and downwardly within the passage 24 . The keel joint arrangement 30 maybe thought of an “open can” arrangement since the can 32 is affixed to the riser 14 by a stress joint (straight or tapered) 38 proximate the lower end of the can 32 while the upper end 40 of the can 32 is not secured to or maintained in contact with the riser 14 . The exemplary stress joint 38 illustrated consists of a pair of radially enlarged collars 42 that surround the riser 14 and are affixed to the inner radial surface of the can 32 . The collars 42 are shown to be fashioned of metal. However, the collars 42 may also be fashioned of a suitable elastomeric material. The collars 42 may be substantially rigid so as to permit a small amount of angular movement of the riser 14 with respect to the can 32 . Alternatively, the collars 42 may be relatively flexible to permit additional angular movement.
[0019] In operation, the riser 14 can move angularly to a degree within the can 32 under bending stresses. Illustrative directions of such relative angular movement are shown in FIG. 2 by arrows 33 about rotation point 35 . During such angular movement, the outer walls of the riser 14 are moved closer to or further away from the inner walls of the keel opening 24 . The stress joint 38 forms a fulcrum. The can 32 is stiff enough that it transfers stresses directly from the stress joint 38 to the supports 34 , thereby preventing any significant stresses from being seen by the upper portion of the riser 14 . Generally, this arrangement allows the upper portion of the riser 14 to have a smaller cross section than the stress joint 38 .
[0020] [0020]FIG. 3 illustrates an alternative embodiment for a keel joint arrangement 50 that is useful as a keel joint 28 . In the keel joint arrangement 50 , a heavy walled wear sleeve 52 radially surrounds a portion of the riser 14 . The wear sleeve 52 may or may not be secured to the riser 14 in a fixed relation, such as by the use of welding or retaining rings such as are known in the art. A central portion of the wear sleeve 52 has an external annular ring 54 that extends radially outwardly and forms the portion of the sleeve 52 having the largest exterior diameter. The ring 54 presents an outer radial surface that is vertically curved in a convex manner. The outer radial surface of the ring 54 may also be frustoconical in shape. Below the annular ring 54 is a lower inwardly tapered portion 56 . Above the ring 54 is an upper inwardly tapered portion 58 . A partially-lined passage, designated as 24 ′, in the hull 22 of the floating vessel 18 has an open upper end 60 that is outwardly flared for installation purposes. The flare of the upper end assists in guiding the sleeve 52 and ring 54 into place when lowering the riser 14 through the hull 22 . The lower end of the passage 24 has an annular recess 62 that is sized and shaped for the annular ring 54 to reside within. The recess 62 presents an inner surface that is vertically curved in a concave manner so that the outer convex surface of the annular ring 54 can be matingly engaged. If the outer radial surface of the ring 54 is frustoconical in shape, however, the inner surface of the recess 62 will be made complimentary to that frustoconical shape.
[0021] In operation, the keel joint arrangement 50 helps to prevent damage to the riser 14 from bending stresses. The wear sleeve 52 is located at the keel 26 where the primary bending stresses are imparted to the riser 14 and, therefore, is designed to absorb most of those stresses and prevent them from being imparted directly to the riser 14 . The interface of the ring 54 and the recess 62 provides a fulcrum wherein the riser 14 can move angularly with respect to the hull 22 . In addition, the elongated upper tapered portion 58 will tend to bear against the length of the passage 24 ′, thereby reducing or eliminating localized, or point, stresses.
[0022] Referring now to FIG. 4, there is shown a keel joint arrangement 70 , which is a second alternative embodiment that is useful as the keel joint 28 . The keel joint arrangement 70 employs centralizer assemblies 72 that are secured within the passage 24 of the hull 22 . Preferably, the centralizer assemblies 72 are spaced angularly about the circumference of the passage 24 . In a preferred embodiment, the centralizers 72 comprise hydraulically actuated piston-type assemblies, the piston arrangement being illustrated schematically by two 72 a , 72 b . In practice, the two arms 72 a , 72 b would be nested one within the other in a piston fashion and would be selectively moveably with respect to one another. In an alternative embodiment, the centralizer assemblies 72 comprise hinged assemblies wherein the two arms 72 a , 72 b are hingedly affixed to one another at hinge point 72 c . Actuation of the centralizer assembly in this case would move the arm 72 a angularly with respect to the arm 72 b about the hinge point 72 c , thereby permitting the arm 72 a to be selectively moved into and out of engagement with the riser 14 . The centralizers 72 are energized via hydraulic lines (not shown) to urge the riser toward the radial center of the passage 24 to resist contact between the riser 14 and the passage 24 . The centralizers 72 have rounded, non-puncturing tips 74 that bear upon the riser 14 . Preferably, the non-puncturing tips comprise either wear pads or rollers for engagement of the riser 14 . It is noted that the piston-type centralizer assemblies 72 may be actuated mechanically rather than hydraulically. Also, the centralizer assemblies' attachments to the passage 24 may be softened, such as through use of springs or rubber, in such a way as to decrease bending stresses by yielding to riser deflection. In a further alternative embodiment, the centralizers 72 will comprise members that have a hinged attachment to the passage 24 .
[0023] [0023]FIG. 5 depicts a third alternative embodiment for the keel joint 28 . Keel joint assembly 90 includes a riser collar 92 that surrounds a portion of the riser 14 proximate the keel 26 . The collar 92 is not affixed to the riser 14 but instead permits sliding movement of the riser 14 upwardly and downwardly through the collar 92 . The collar 92 is generally cylindrical but includes a bulbous central portion 94 and two tapered end portions 96 , 98 . A guide sleeve 100 radially surrounds the collar 92 and features an interior rounded profile 102 that is shaped and sized to receive the bulbous portion 94 of the collar 92 . An exterior landing profile 104 is located at the lower end of the guide sleeve and is shaped and sized to form a complementary fit with a landing profile 106 formed into the keel 26 . The passage 24 ′ is constructed identically to the passage 24 ′ described earlier in that it has an open upper end with an outward flare.
[0024] To assemble the keel joint arrangement 90 , the collar 92 and guide sleeve 100 are assembled onto the riser 14 . Then the riser 14 is run through the passage 24 ′ and the landing profile 104 of the guide sleeve 100 is seated into the matching profile 106 in the keel 26 . In operation, the riser 14 can slide upwardly and downwardly within the collar 92 as necessary to compensate for movement of the floating platform 18 . Rotation of the platform 18 with respect to the riser 14 is permitted between the riser 14 and the collar 92 as well as between the collar 92 and the guide sleeve 100 . Angular movement of the riser 14 with respect to the platform 18 is accommodated by rotation of the bulbous portion 94 within the rounded profile 102 of the guide sleeve 100 . Alternatively, a rubberized flex joint of a type known in the art (not shown) might be used to accommodate angular rotation.
[0025] A fourth alternative exemplary embodiment for the keel joint 28 is shown in FIG. 6. Keel joint assembly 110 incorporates a flexible cage assembly to permit relative movement between the riser 14 and the floating vessel 18 . A flexible cage assembly 112 is formed of an inner riser sleeve 114 and an outer keel sleeve 116 . A central cage 118 adjoins the two sleeves 114 , 116 . The cage 118 includes an upper ring 120 , a central ring 122 , and a lower ring 124 . There are a series of upper spokes 126 that radiate upwardly and outwardly from the central ring 122 to the upper ring 124 . There are also a series of lower spokes 128 that radiate outwardly and downwardly from the central ring 122 to the lower ring 124 . The upper and lower spokes 126 , 128 are each arranged in a spaced relation from one another about the circumference of the central ring 122 . The spokes 126 , 128 are fashioned from a material that is somewhat flexible yet has good strength under both tension and compression. It is currently preferred that the spokes 126 , 128 are fashioned of a steel alloy, although other suitable materials may be used. The spokes 126 , 128 are elastically deformable as necessary to allow the riser 14 to move angularly within the passage 24 ′. Angular deflection of the riser 14 results in non-uniform deflection of upper spokes 126 and lower spokes 128 . The upper ring 120 affixes the upper spokes 126 to the outer keel sleeve 116 . The lower ring 124 is not affixed to the outer keel sleeve 116 .
[0026] The outer keel sleeve 116 is seated within the passage 24 ′ by means of a landing profile 130 that is shaped and sized to be seated within a complimentary seating profile 132 at the lower end of the passage 24 ′. Locking flanges 134 are secured onto the lower side of the keel 26 to secure the outer keel sleeve 116 in place. In a manner known in the art, the locking flanges 134 may be selectively disengaged, or unlocked, and subsequently retrieved by upward movement of the riser 14 with respect to the passage 24 ′, i.e., by pulling upwardly on the riser string.
[0027] During operation, the cage 118 holds the riser 14 in a semi-rigid manner that permits some flexibility. The riser 14 can move angularly with respect to the hull 22 due to the flexibility of the spokes 126 and 128 of the cage 118 . Loading from movement of the riser 14 is transferred by the upper spokes 126 to the keel sleeve 116 which, in turn transfers the loading to the hull 22 . Because the keel sleeve 116 engages the passage 24 ′ of the hull 22 along substantially its entire length, point loading is avoided.
[0028] [0028]FIG. 7 depicts a fifth alternative embodiment for use as the keel joint 28 . Keel joint arrangement 130 includes an open top can structure, which is shown incorporated into the riser 14 as a sub 132 at is affixed at either end to other riser sections 134 , 136 . The can sub 132 includes a pair of concentric tubular members. The inner tubular member 138 has the same interior and exterior diameters as a standard riser section. The outer tubular member, or can, 140 is coaxial with the inner tubular member 138 and is affixed to the inner tubular member 138 by a flange adapter, or stress joint, 142 that joins the two pieces together proximate the lower end of the sub 132 . While FIG. 7 shows the flange adapter 142 to be an annular metallic collar that is integrally formed into both the inner and outer tubular members 138 , 140 , it might also comprise a separate collar or elastomeric member as well as a flexible casing.
[0029] A cylindrical guide sleeve 144 radially surrounds the open top can sub 132 . The guide sleeve 144 is securely affixed to the outer tubular member 140 by, for example, welding. Supports 146 are used to secure the guide sleeve 144 within the passage 24 of the hull 22 . The supports 146 maintain the guide sleeve 144 a distance away from the wall of the passage 24 so that the guide sleeve 144 is substantially radially centered within the passage 24 . The supports 146 are preferably formed of structural beams. The supports 146 are arranged in two tiers, an upper tier and a lower tier, and each tier surrounds the circumference of the passage 24 . The outer tubular member 140 is stiff enough that it transfers stresses directly from the flange adapter 142 to the guide sleeve 144 . Because the guide sleeve 144 and the outer tubular member 140 are affixed along substantially their entire length, point stresses are avoided. In addition, the supports transmit loads or stresses from the guide sleeve 144 to the passage 24 walls. The length of contact between the outer tubular member 140 and the guide sleeve 144 allows for a longer vertical riser stroke than arrangements wherein there is less contact area, such as the arrangement 30 shown in FIG. 2.
[0030] While described in terms of preferred embodiments, those of skill in the art will understand that many modifications and changes may be made while remaining within the scope of the invention. | Keel joint assemblies are described that permit a degree of rotational movement of a riser within the keel of a floating vessel and greatly reduce the amount of stress and strain that is placed upon the riser, as well. Keel joint assemblies described provide a limiting joint between the riser and the keel opening that permits some angular rotation of the riser with respect to the floating vessel. Additionally, the limiting joint permits the riser to move upwardly and downwardly within the keel opening, but centralizes the riser with respect to the keel opening so that the riser cannot move horizontally with respect to the keel opening. In described embodiments, the limiting joint is provided by a single annular joint that allows that riser to move angularly with respect to the can. In some embodiments, the keel joint assembly incorporates a cylindrical stiffening can that radially surrounds a portion of the riser and is disposed within the keel opening. In these embodiments, a flexible joint is provided between the can and the riser. Supports or guides may be used to retain the can within the keel opening. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of international patent application no. PCT/EP2006/060253, filed Feb. 24, 2006 designating the United States of America and published in German on Aug. 31, 2006 as WO 2006/089945, the entire disclosure of which is incorporated herein by reference. Priority is claimed based on Federal Republic of Germany patent application no. DE 10 2005 008 923.2, filed Feb. 24, 2005.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a valve module and to a filter device incorporating such a valve module.
[0003] Diaphragm valves, which are intended to control a fluid flow, are known. An example of diaphragm valves of this type is shown in FIG. 5 . The following reference numerals relate to this figure. The diaphragm valve has a valve housing 101 , to which a diaphragm 103 is attached. A valve housing cover 102 is situated above the diaphragm 103 , which is connected to the diaphragm 103 to form a seal. An inlet 104 and an outlet 105 are situated in the valve housing 101 , the inlet 104 being separated from the outlet 105 by the diaphragm 103 to form a seal below a predefined pressure level. When the predefined pressure level is exceeded, the diaphragm 103 lifts off of a valve seat 106 situated on the valve housing 101 . The fluid may thus flow from the inlet 104 to the outlet 105 . The diaphragm valve is connected to fluid lines, which supply the fluid to the diaphragm valve and drain it therefrom. This diaphragm valve requires a relatively large amount of space, because the fluid is conducted through the valve housing 101 .
SUMMARY OF THE INVENTION
[0004] The object of the present invention is to provide an improved diaphragm valve module.
[0005] Another object of the invention is to provide a valve module which requires less overall space than prior designs.
[0006] A further object of the invention is to provide a valve module which is cost-effective.
[0007] These and other objects are achieved in accordance with the present invention by providing a valve module for controlling a fluid flow comprising a valve having a valve cover, a valve body, and a valve seat, in which the valve body is configured to matingly correspond to the valve seat; the valve seat is integrated in an adapter plate; the valve body and the valve cover are attached to the adapter plate in a sealed manner to form a control chamber; and the adapter plate has an unfiltered fluid channel and a filtered fluid channel situated inside the adapter plate, an inlet leading to the unfiltered fluid channel, and an outlet leading from the filtered fluid channel.
[0008] The valve module according to the present invention is used for controlling a fluid flow, in particular a liquid flow to be filtered. The valve module comprises a valve having a valve cover, a valve body, and a valve seat. The valve body matingly engages the valve seat, which advantageously may be integrated in an adapter plate. The valve body and the valve cover are connected to the adapter plate, the adapter plate having an inlet and an outlet. An unfiltered fluid channel and a filtered fluid channel are situated inside the adapter plate. The valve body may have any desired configuration, e.g., as a ball or plate. Because the adapter plate forms the valve seat, a valve bottom part may be omitted. Overall space is thus saved on one hand, and guidance of the flow is simplified on the other hand, because the fluid flow is guided in the adapter plate in any case.
[0009] In accordance with one advantageous embodiment of the invention, the valve seat is press-fit into the adapter plate. If desired, a different material may be selected for the valve seat than for the adapter plate. Furthermore, the valve seat may be machined on different machines than the adapter plate.
[0010] In another advantageous embodiment of the invention, the valve body is a resilient or elastic diaphragm. It may comprise different areas. Preferably, the diaphragm has a boundary zone which is connected to the adapter plate, by which exact positioning of the diaphragm is achieved and slipping is prevented.
[0011] It is advantageous if the adapter plate is provided with a valve in the area of the filtered fluid channel, with which the filtered fluid channel can be closed. The filtered fluid channel may thus be closed or opened as needed. This is advantageous when replacing attachment parts.
[0012] In accordance with a further advantageous embodiment of the present invention, the adapter plate is provided with a valve in the area of the unfiltered fluid channel, with which the unfiltered fluid channel can be closed. Therefore, downstream components may be changed without any undesired discharge of fluid from the overall device.
[0013] In one refinement of the present invention, the filtered fluid channel is provided with at least two valves arranged in parallel, which close or open two separate channels independently of one another. Therefore, only one single channel or all channels may have flow through them as needed. This is especially significant for the flow through components situated downstream.
[0014] The filter device according to the present invention is used for filtering a fluid, in particular a processing fluid. Processing fluids in the sense of the present patent application include gases or liquids which are used, for example, to carry away chips or cuttings created during the machining of workpieces or the production of products. For example, the processing fluid may be an air stream or a coolant and/or lubricant, which carry away severed material from the workpiece and/or protect the tool. The filter device comprises a valve module as described above, a container, an unfiltered fluid connection, and a filtered fluid connection. At least one filter unit stack is arranged in the container and is connected to the valve module. The valves serve to individually activate or actuate the filter unit stacks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be described in further detail hereinafter with reference to illustrative preferred embodiments shown in the accompanying drawing figures, in which:
[0016] FIG. 1 is a side elevation view of a filter device according to the present invention;
[0017] FIG. 1 a is a schematic view of a filter device according to the invention;
[0018] FIG. 2 is a sectional view of an adapter plate for the valve of the invention;
[0019] FIG. 3 is a sectional view of a valve in the filtered fluid channel taken along line A-A of FIG. 2 ;
[0020] FIG. 4 is a sectional view of a valve in the unfiltered fluid channel taken along line B-B of FIG. 2 , and
[0021] FIG. 5 is a sectional view of a prior art diaphragm valve.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] A filter device is schematically illustrated in FIG. 1 . The filter device comprises a valve module 10 , which is formed by an adapter plate 11 and valves 12 . The valves 12 each comprise a flexible elastic diaphragm 13 and a valve cover 14 . The diaphragm 13 and the valve cover 14 are attached to the adapter plate 11 . The diaphragm 13 contacts a valve seat 15 , which is integrated into the adapter plate, e.g., by constructing it in one piece with the adapter plate or by press-fitting it into the adapter plate. A filter unit stack 16 , which is composed of individual filter units as are known in the prior art, adjoins the adapter plate 11 . Multiple filter unit stacks 16 may also be arranged in parallel to increase the filter area. These multiple filter units produce a filter unit module 16 a . The filter units each comprise a filter medium, an unfiltered fluid channel, and a filtered fluid channel. The filter unit stack 16 is closed on the side situated opposite the adapter plate 11 by a clamping plate 17 . The entire unit composed of the valve module 10 , the filter unit stack 16 , and the clamping plate 17 is situated in a vessel or container 18 . The unfiltered fluid connection 19 opens into an unfiltered fluid channel 20 in the adapter plate 11 . The fluid to be filtered may be introduced into the filter device through the unfiltered fluid connection 19 . Furthermore, the adapter plate 11 comprises a filtered fluid channel 22 , which is connected to a collecting vessel 23 . The filtered fluid is discharged from the filter device. A part of the fluid is stored in the collecting vessel 23 until it is needed to backwash the filter units. A filtered fluid connection 21 , through which the fluid may be drawn out, may be provided for removing the filtered fluid. However, as an alternative, the collecting container 23 also may be exchanged when full.
[0023] A filter bag 24 , which is situated in a drawer 25 , is situated below the container 18 . A concentrate drain 26 , which is closable by the valve 12 disposed in the unfiltered fluid channel 20 , discharges into the filter bag 24 .
[0024] The fluid to be filtered flows through the unfiltered fluid connection 20 into the adapter plate 11 . The valve 12 in the unfiltered fluid channel 20 is closed, as a result of which the fluid flows through the filter unit stack 16 . The valves 12 in the filtered fluid channel 22 are opened, so that the filtered fluid flows through the filtered fluid channel 22 into the collecting vessel 23 .
[0025] After a defined time interval, and/or as needed, the filter units of the filter unit stack 16 may be regenerated. For this purpose, the valve 12 in the filtered fluid channel 22 of the filter unit stack 16 which is to be cleaned is opened, and the valves 12 of the filter unit stacks 16 which are not to be regenerated are closed. The valve 12 in the unfiltered fluid channel 20 is opened. The filtered fluid impinges against the filter units and flows back through them in the opposite flow direction. The deposits on the inflow side of the filter unit are thus removed and flushed through the concentrate drain into the filter bag 24 . After this backwashing procedure, the valve 12 in the unfiltered fluid channel 20 closes again, and the filter device is again ready to filter unfiltered fluid.
[0026] The valves 12 are activatable using a control fluid, in particular compressed air. The control fluid is introduced between the diaphragm 13 and the valve cover 14 with sufficient pressure that the diaphragm 13 is not lifted off from the valve seat 15 in normal operation. When the valve 12 is to be opened, the pressure of the control fluid is reduced and the diaphragm 13 thus lifts off from the valve seat 15 .
[0027] A filter device according to FIG. 1 is schematically illustrated in FIG. 1 a . The filter device comprises a container 18 , in which a filter unit module 16 a comprising four filter unit stacks 16 is situated. The filter unit module 16 a has an unfiltered fluid connection 19 , which may be opened and closed using a valve 12 a . The unfiltered fluid connection 19 is connected to the unfiltered fluid channel 20 ′ of each filter unit stack 16 . The filtered fluid channels 22 ′ of the filter unit stacks 16 are connected to a filtered fluid channel 22 , with each filter unit stack 16 being able to be opened and closed using a separate valve 12 c.
[0028] The filtered fluid channel 22 discharges on one hand into a collecting vessel 23 and on the other hand into a filtered fluid container 23 ′. The filtered fluid container 23 ′ can be shut off from the filtered fluid line 22 using a valve 12 d . The unfiltered fluid connection 19 is connected to an unfiltered fluid container R, and a pump P is provided to force the fluid to be filtered into the filter unit module 16 a . Furthermore, the unfiltered fluid connection 19 is connected to a concentrate drain 26 , which discharges into a filter bag 24 . The concentrate drain 26 may be opened and closed via a valve 12 b.
[0029] The container 18 is provided with a drain line A which discharges into a further container 18 ′. The container 18 ′ is connected to an unfiltered fluid container R such that fluid collected in the container 18 ′ may be returned to the unfiltered fluid container R by opening the valve 12 ′.
[0030] A sensor S 1 for detecting a minimum level status and a sensor S 2 for detecting a maximum level status are provided for detecting the liquid level in the container 18 ′. As soon as the liquid level is detected by the sensor S 2 , the valve 12 ′ is opened. After the level falls below sensor S 1 , the valve 12 ′ is closed again.
[0031] The fluid to be filtered starts out in the unfiltered fluid container R. From there, it is pumped with valve 12 a open through the unfiltered fluid connection 19 into the filter unit module 16 a . In this state, the valve 12 b is closed. At least one of the valves 12 c is open, so that the filtered fluid may exit from the filter unit module 16 a through the filtered fluid channel 22 . The filtered fluid flows into the collecting vessel 23 or, with valve 12 d open, into the filtered fluid container 23 ′, from where it is supplied for its further use.
[0032] If one or more of the filter unit stacks 16 becomes loaded with dirt, the valve 12 d is closed and the respective valve 12 c is opened so that the filter unit stack 16 a may be backwashed. For this purpose, the valve 12 a is also closed and the valve 12 b into the concentrate drain 26 is opened. The contaminated backwashing fluid is collected in the filter bag 24 . When the fluid contained in the filter unit module 16 a may not be filtered further, the fluid is removed from the filter unit module via the concentrate drain 12 b . When the bag 24 is full, it is replaced or emptied. The concentrate is then disposed of. Because the filter units of the filter unit stack 16 are only clamped against one another, slight leaks may occur. These are collected in the container 18 and removed from the container 18 via the drain line A.
[0033] A respective pressure switch D, which detects the pressure level in the particular channel, is situated both in the filtered fluid channel 22 and also in the unfiltered fluid channel 20 .
[0034] An adapter plate 11 is illustrated in a sectional view in FIG. 2 . Components in FIG. 2 corresponding to those of FIG. 1 are identified by the same reference numerals. The unfiltered fluid channel 20 in the adapter plate 11 is represented by two holes extending diagonally downward toward the middle, with one hole being closed to the outside. The other hole forms an inlet 27 , through which the fluid to be filtered is introduced into the adapter plate 11 . The unfiltered fluid channel 20 has distributor holes 28 , which are situated in such a way that they correspond to the filter unit stacks 16 . Furthermore, the number of the distributor holes 28 is matched to the number of the filter unit stacks 16 so that each filter unit stack 16 has its own distributor hole. The valve seat 15 for the valve 12 provided in the unfiltered fluid channel 20 is situated in the middle, where the two holes meet.
[0035] The filtered fluid channel 22 also is formed by a bore hole, with a vertically extending bore hole meeting a horizontally extending bore hole. The filtered fluid exits again from the adapter plate 11 through the vertical hole. Openings 29 , whose number corresponds to the number of filter unit stacks 16 , are situated in the horizontally extending hole. A valve seat 15 for a valve 12 is situated in each of these openings 29 . Furthermore, the horizontally extending hole is closed on its front sides in operation.
[0036] FIG. 3 shows a valve 12 in the filtered fluid channel 22 in a sectional view taken along line A-A of FIG. 2 , and FIG. 4 shows a valve 12 in the unfiltered fluid channel 20 in a sectional view taken along line B-B of FIG. 2 . The construction of the valves 12 is identical in both figures. Again, components corresponding to FIG. 1 or FIG. 2 are identified by the same reference numerals. The diaphragm 13 and the valve cover 14 are connected to one another and to the adapter plate 11 in a sealed manner.
[0037] A control chamber 30 , which is connected via a solenoid valve 31 a to a control fluid line 31 , is formed between the diaphragm 13 and the valve cover 14 . A control fluid may be introduced into the control chamber 30 through the control fluid line 31 using the solenoid valve 31 a , such that the control pressure required in the control chamber 30 can be adapted to the particular operating state of the valve 12 . When the valve 12 is closed or kept closed, a higher control pressure is necessary than when the valve 12 is opened.
[0038] The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the described embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations within the scope of the appended claims and equivalents thereof. | A valve module for control of a fluid flow, especially flow of a fluid to be filtered in a filter apparatus. The valve module includes a valve ( 12 ) with a valve cover ( 14 ) a valve body ( 13 ) and a valve seat ( 15 ). The valve body mates with the valve seat ( 15 ), which is integrated in an adapter plate ( 11 ). The adapter plate ( 11 ) is provided with an inlet ( 27 ) and an outlet, with an unfiltered fluid channel ( 20 ) and a filtered fluid channel ( 22 ) arranged in the adapter plate. The integration of the valve seat ( 15 ) and unfiltered and filtered fluid channels ( 20, 22 ) in the adapter plate ( 11 ) makes possible a space-saving construction of the valve ( 12 ). | 1 |
The present application claims priority on European Patent Application 01307865.4 filed on 14 Sep. 2001.
FIELD OF THE INVENTION
The present invention relates to a drilling system and a method for drilling a borehole into an earth formation, the drilling system comprising pump means for pumping drilling fluid into the borehole and discharge means for discharging drilling fluid from the borehole.
The drilling system may furthermore comprise a drill string extending into the borehole whereby an annular space is formed between the drill string and the borehole wall, the annular space containing a body of drilling fluid. The drill string generally has a longitudinal passage for pumping drilling fluid into the annular space through a opening near the lower end of the drill string. The drilling fluid can be discharged from the borehole through a discharge conduit connected with the borehole near the upper end of said annular space. The flow of drilling fluid through said annular space can be controlled by said discharge means, for example by a controllable resistance in said discharge conduit.
Therefore the discharge conduit can be provided with a choke valve providing a controllable throttle opening. However, because of rock debris and contaminated mud in the drilling fluid a throttle opening in the discharge conduit shall be worn out soon.
BACKGROUND OF THE INVENTION
WO-A-0079092 discloses such drilling system, whereby the discharge means control the discharge of drilling fluid,and therewith the flow of drilling fluid through the annular space. Therefore the discharge conduit is provided with a controllable outlet valve. As an alternative WO-A-0079092 describes an injection pump arranged to pump injection fluid via an injection nozzle into the discharge conduit in a direction opposite to the direction of flow of drilling fluid through the discharge conduit. By controlling the injection fluid, the resistance in the discharge conduit can be controlled.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided a drilling system for drilling a borehole into an earth formation, the drilling system comprising pump means for pumping drilling fluid into the borehole and discharge means for discharging drilling fluid from the borehole, wherein the discharge means comprises at least one pressure chamber for temporarily accommodating drilling fluid being discharged from the borehole, and control means for controlling the fluid inflow into each pressure chamber.
Thereby it is achieved that the drilling fluid from the borehole is transported to the pressure chamber and the inflow of it into the pressure chamber can be controlled without a restriction through which the drilling fluid has to flow.
Preferably said control means is arranged to control the fluid pressure in the pressure chamber.
The inflow of drilling fluid into the pressure chamber can be controlled by controlling the outflow of gas or liquid which is expelled from the pressure chamber by the inflow of drilling fluid. Such gas or liquid, hereinafter referred to as expel fluid, can be led through a controllable throttle opening, thereby controlling the inflow of drilling fluid. In fact thereby the said control means control fluid pressure above the drilling fluid in the pressure chamber.
In fact the discharge of drilling fluid from the borehole is controlled by throttling the expel fluid in stead of throttling the drilling fluid. And because the expel fluid does not contain rock debris or contaminated mud, there is no wear problem in the choke valve throttling the fluid.
Preferably the pressure chamber is provided with two compartments separated by a flexible membrane, whereby one of the compartments is to be filled with drilling fluid and the other compartment contains an expel fluid, whereby said control means control the outflow of said expel fluid from the pressure chamber.
In a preferred embodiment two or more pressure chambers being alternately filled with drilling fluid from the borehole, whereby said control means control the inflow of drilling fluid in each of the pressure chambers. By making use of more than one pressure chamber, the drilling fluid can be removed from a pressure chamber while the drilling fluid from the borehole can be led to another pressure chamber.
Preferably two pressure chambers are interconnected by an expel fluid conduit for transporting an expel fluid between the two pressure chambers, whereby said control means comprise a control valve in said expel fluid conduit.
In a preferred embodiment the discharge means comprise two pressure chambers, each provided with a membrane to form a drilling fluid compartment and an expel fluid compartment, both having a variable content, the expel fluid compartments being interconnected by an expel fluid conduit provided with a control valve for controlling flow through said expel fluid conduit, the system furthermore being provided with inlet valve means to direct the drilling fluid to be discharged alternately to one of said drilling fluid compartments and with outlet valve means to remove drilling fluid from the other drilling fluid compartment.
The invention furthermore relate to a method for drilling a borehole into an earth formation, whereby drilling fluid is pumped into the borehole and whereby drilling fluid is discharged from the borehole and transported to a pressure chamber, whereby the inflow of drilling fluid into the pressure chamber is controlled.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail and by way of example with reference to the accompanying drawing in which:
FIG. 1 schematically shows an embodiment of a drilling system; and
FIGS. 2 and 3 schematically show the drilling fluid discharge means.
In the figures like reference numerals relate to like components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 is shown a drill string 1 extending into a borehole 3 formed in an earth formation 5 and provided with a drill bit 7 and a bottom hole assembly (BHA, not shown). The drill string 1 is made up of a plurality of drill string joints, whereby each pair of adjacent joints is interconnected by a releasable connector. For the purpose of clarity only one of the uppermost connectors 9 a , 9 b , which connects the uppermost joint to the remainder of the drill string 1 , is shown (in disconnected mode). In the description hereinafter, the upper drill string joint is referred to as the upper drill string section 10 and the remainder of the drill string 1 is referred to as the lower drill string section 12 . The lower drill section 12 is supported at rig floor 14 of a drilling rig (not shown) by power slips 16 . The upper drill string section 10 is supported by a top drive 18 which is capable of supporting the entire drill string 1 and which is provided with a drive system (not shown) for rotating the drill string 1 during drilling. A primary pump 19 is in fluid communication with the upper drill string section to pump drilling fluid through the drill string 1 when the connector 9 a , 9 b is in connected mode.
A fluid chamber 20 is supported by a support column 22 provided at rig floor 14 in a manner allowing the fluid chamber 20 to move up or down along the column 22 , and means (not shown) are provided to control such movement. The upper drill string section 10 extends into the fluid chamber 20 through an upper opening 24 of the fluid chamber 20 so that the open lower end of the upper drill string section 10 is located in an upper portion 25 of the chamber 20 . The lower drill string section 12 extends into the fluid chamber 20 through a lower opening 26 of the fluid chamber 20 so that the open upper end of the lower drill string section 12 is located in a lower portion 27 of the chamber 20 . Both upper opening 24 and de lower opening 26 are of a sufficiently large diameter to allow passage of the drill string connectors (which generally are of slightly larger diameter than the drill string sections) therethrough. Furthermore, the upper and lower openings 24 , 26 are provided with seals 29 a , 29 b which are controllable so as to be moved radially inward and thereby to seal against the respective upper and lower drill string sections 10 , 12 . The lower portion 27 of chamber 20 is provided with a fluid inlet 28 in fluid communication with a secondary pump 30 to pump drilling fluid through the lower drill string section 12 when the connector 9 a , 9 b is in disconnected mode.
The upper portion 25 and the lower portion 27 of the fluid chamber 20 are selectively sealed from each other by a partitioning means in the form of a valve 32 . A control device (not shown) is provided to open or close the valve 32 , whereby in its open position the valve 32 allows passage of drill string 1 through the valve 32 . Furthermore, in the open position of the valve 32 , the upper portion 25 and the lower portion 27 of the fluid chamber 20 are in fluid communication with each other. A pair of power tongues 34 , 36 connecting and disconnecting the connector 9 a , 9 b is attached to the fluid chamber 20 at the lower side thereof.
An annular space 38 is defined between the lower drill string section 12 on one hand and the borehole wall and a wellbore casing 42 on the other hand, which annular space is filled with a body of drilling fluid 40 . The annular space 38 is at its upper end sealed by a rotating blowout preventor (BOP) 46 which allows rotation and vertical movement of the drill string 1 . A drilling fluid discharge conduit 48 is provided at the upper end of the annular space 38 , which discharge conduit 48 debouches into a drilling fluid reservoir (not shown) via discharge means 50 , which discharge means shall be elucidated hereinafter referring to FIGS. 2 and 3 . A tertiary pump 52 is arranged in parallel with the discharge means 50 , which pump 52 is in fluid communication with the discharge conduit 48 at a branch connection 54 located between the discharge means 50 and the rotating BOP 46 . The pump 52 is operable so as to pump drilling fluid from a drilling fluid reservoir (not shown) into the annular space 38 . The lower part of the drill string 1 is provided with means for controlling the flow of drilling fluid from the body of drilling fluid 40 into the drill string 1 in the form of a non-return valve (not shown) which prevents such return flow.
During normal operation the drill string 1 is rotated by the top drive 18 to further drill the borehole 3 whereby the connector 9 a , 9 b is in connected mode. A stream of drilling fluid is pumped by primary pump 19 via the drill string 1 and the drill bit 7 into the annular space 38 where drill cuttings are entrained into the stream. The stream then flows in upward direction through the annular space 38 and via the discharge conduit 48 and the discharge means 50 into the drilling fluid reservoir (not shown). The fluid pressure in the annular space 38 is controlled by controlling the pump rate of pump 19 and/or by controlling the discharge means 50 and/or the tertiary pump 52 .
When it is desired to remove the drill string from the borehole 3 , the individual drill strings joints are to be disconnected and removed from the drill string 1 in sequential order. This is done by disconnecting and removing the uppermost joint, moving the drill string 1 upwardly to a position wherein the joint which is now the. uppermost joint can be removed, etc. To remove the uppermost joint (i.e. drill string section 10 ) the following procedure is followed. Rotation of the drill string 1 by the top drive 18 is stopped while drilling fluid is continuously circulated through the drill string by operation of primary pump 19 . The fluid chamber 20 is moved along support column 22 to a position where the power tongues 34 , 36 are located at the level of the connector 9 a , 9 b , whereupon the tongues 34 , 36 are operated so as to break out and partly unscrew the connector 9 a , 9 b . The connector 9 a , 9 b is unscrewed by the slips only to the extent that further unscrewing can be done by the top drive 18 . The fluid chamber 20 is then moved along support column 22 so as to position connector 9 a , 9 b inside the lower fluid chamber portion 27 , and the seals 29 a , 29 b are moved radially inward so as to seal against the respective upper and lower drill string sections 10 , 12 . The secondary pump 30 is operated to pressurise fluid camber 20 . The top drive is then rotated in counter clockwise direction thereby further unscrewing the connector 9 a , 9 b . Once the connector 9 a , 9 b becomes disconnected the upper drill string section 10 is raised a short distance so as to position the upper connector half 9 a in the upper portion 25 of the fluid chamber 20 . The valve 32 is closed so as to seal the upper fluid chamber portion 25 from the lower fluid chamber portion 27 . Simultaneously with closing the valve 32 the primary pump 19 is stopped and the secondary pump 30 is operated to pump drilling fluid through the fluid inlet 28 into the lower fluid chamber portion 27 and from there through lower drill string section 12 into the annular space 38 . The seal 29 a is retracted to remove the upper drill string section, and the drill string joint which has now become the uppermost joint is connected to the top drive 18 . The procedure described heretofore is repeated in order to remove the now uppermost drill string joint. By the continued circulation of drilling fluid through the borehole 3 it is achieved that undesired settling of particles (e.g. drill cuttings) in the borehole occurs, and that the fluid pressure in the borehole can be controlled by controlling the pump rate of pump 30 and/or controlling the discharge means 50 .
Instead of using the secondary pump 30 to pump drilling fluid through the lower drill string section 12 when the connector 9 a , 9 b is disconnected, the primary pump 19 can be used for this purpose in which case the primary pump 19 is connected to the fluid inlet 28 by suitable conduit means.
The above procedure relies on the use of the fluid chamber 20 to control the fluid pressure in the borehole by continued fluid circulation through the drill string 1 when the upper drill string section 10 is disconnected. In case it is impractical or impossible to use the fluid chamber an alternative procedure can be applied to connect or disconnect the upper drill string section 10 to or from the drill string 1 . In the alternative procedure, which can be applied in the absence of the fluid chamber, the tertiary pump 52 is operated so as to pump drilling fluid through the circuit formed by the pump 52 , the branch connection 54 , and the discharge means 50 . By controlling the pump rate of pump 52 and/or by controlling the discharge means 50 the fluid pressure in the annular space 38 can be controlled. The non-return valve in the drill string 1 prevents flow of drilling fluid from the annular space 38 into the drill string 1 . The alternative procedure can be used, for example, in case drill string stabilisers prevent passage of the drill string through the fluid chamber.
An advantage of continued fluid circulation through the drill string 1 using the fluid chamber 20 when the upper drill string joint are disconnected, is that the drilling fluid in the open part of the borehole 3 keeps flowing so that undesired settling of particles in the borehole is prevented. However once the drill string has been raised to a level whereby the drill bit 7 is located within the casing 42 , the drilling fluid which is pumped through the drill string 1 returns from the bit 7 through the annular space 38 to surface thereby leaving the drilling fluid in the open part of the borehole 3 stationary. It is therefore preferred that, once the drill bit 7 is within the casing 42 , pumping of drilling fluid by secondary pump 30 is stopped and pumping by tertiary pump 52 is commenced to control the fluid pressure in the borehole. This procedure has the advantage that the fluid chamber 20 then is no longer required and can be removed from the drill string.
FIGS. 2 and 3 show the discharge means 50 in more detail. The flow of drilling fluid to be discharged is supplied to the discharge means by discharge conduit 48 .
The discharge means comprise two pressure chambers 60 , 61 . Each pressure chamber is provided with a membrane 62 , 63 made out of flexible material, such as rubber. The membrane 62 , 63 divides each pressure chamber 60 , 61 in two compartments, a drilling fluid compartment 64 , 65 and an expel fluid compartment 66 , 67 . Both expel fluid compartments 66 , 67 are interconnected by an expel fluid conduit 68 passing a control valve 69 , which control valve 69 is a choke valve for controlling the flow of expel fluid through conduit 68 by throttling that flow.
The drilling fluid compartment 64 , 65 of each pressure chamber 60 , 61 is provided with inlet valve means ( 70 , 71 ) to direct the drilling fluid to be discharged to the drilling fluid compartment 64 or 65 respectively, and is provided with outlet valve means ( 72 , 73 ) to remove drilling fluid from the drilling fluid compartment 64 or 65 respectively.
FIG. 2 shows a first mode of the discharge means and FIG. 3 shows a second mode.
In the first mode, as shown in FIG. 2 , inlet valve 70 is open and inlet valve 71 is closed. Furthermore outlet valve 72 is closed and outlet valve 73 is open. The flow of drilling fluid is indicated with arrows 75 . From conduit 48 the drilling fluid flows to drilling fluid compartment 64 , whereby the membrane 62 is moved upwardly. Therefore expel fluid is expelled from compartment 66 through conduit 68 to expel fluid compartment 67 , thereby passing choke valve 69 . The flow of expel fluid is indicated with arrows 76 . The inflow of expel fluid into compartment 67 moves the membrane 63 downward, expelling the drilling fluid from compartment 65 , which drilling fluid can be further transported, for example to a filtering system (not shown).
The flow of drilling fluid to compartment 64 is controlled by controlling choke valve 69 up to the moment that drilling fluid compartment 64 is completely filled with drilling fluid. At that moment the discharge means are shifted to the second mode as shown in FIG. 3 .
In the second mode, as shown in FIG. 3 , inlet valve 70 is closed and inlet valve 71 is open. Furthermore outlet valve 72 is open and outlet valve 73 is closed. The flow of drilling fluid is indicated with arrows 75 . From conduit 48 the drilling fluid flows to drilling fluid compartment 65 , whereby the membrane 63 is moved upwardly. Therefore expel fluid is expelled from compartment 67 through conduit 68 to expel fluid compartment 67 , thereby passing choke valve 69 . The flow of expel fluid is indicated with arrows 76 . The inflow of expel fluid into compartment 66 moves the membrane 62 downward, expelling the drilling fluid from compartment 64 , which drilling fluid can be further transported, for example to a filtering system (not shown).
During operation of the discharge means the first and the second mode will alternate with each other, whereby the choke valve 69 may be maintained in the same position to achieve a predetermined resistance in expel conduit 68 in both modes. That will result in a constant resistance for the drilling fluid passing the discharge means. By changing the position of the choke valve 69 that resistance will be changed.
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be readily apparent to, and can be easily made by one skilled in the art without departing from the spirit of the invention. Accordingly, it is not intended that the scope of the following claims be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all features which would be treated as equivalents thereof by those skilled in the art to which this invention pertains. | A drilling system is provided for drilling a borehole into an earth formation, the drilling system comprising pump means for pumping drilling fluid into the borehole and discharge means for discharging drilling fluid from the borehole. The discharge means comprises at least one pressure chamber for temporarily accommodating drilling fluid being discharged from the borehole, and control means for controlling the fluid inflow into each pressure chamber. | 4 |
FIELD OF INVENTION
This invention relates to pet and child protection, in particular to devices, systems and methods of mounting plastic translucent and/or advertising panels to balconies, banisters and stair railings and across openings between posts using magnetic fasteners and clips, to protect pets and small children.
BACKGROUND AND PRIOR ART
Balconies on condominium and apartment buildings often having railings with spaced apart posts that are generally spaced apart from one another by approximately 6 to approximately 8 inches. While the spacing may be narrow enough to prevent large children from passing through, the spacing is large enough to allow for small children and pets to pass through. In high rises, it has been known that pets, such as cats and dogs have fallen through the spacing, which can result in the pet falling a large distance to ground level below. Similarly, this problem also exists with banisters and stairwells having open post supported railings.
Various attempts have been made over the years to cover the spacing between the support posts. Kidshield Indoor Banister Guard and Clear Banister Guard Kit are two products on the market which generally include translucent plastic panels for covering banister openings. However, both products are not easy to install and remove.
Both products require the installer having to hole punch the plastic sheets in order to and use screw type fasteners and cable ties to fasten the sheets to walls and posts. In addition to causing permanent damage to underlying surfaces, the screws must be each manually attached which can be tedious and time consuming. And both the screws and cable ties are an unsightly when looking at the covered banisters. Furthermore, punching holes in the plastic panels will weaken the panels, and can result in the panels tearing and ripping apart.
Thus, the need exists for solutions to the above problems with the prior art.
SUMMARY OF THE INVENTION
A primary objective of the present invention is to provide devices, systems and methods of mounting plastic translucent and/or advertising panels to balconies, banisters and stair railings using magnetic fasteners and clips, to protect pets and small children.
A secondary objective of the present invention is to provide devices, systems and methods of mounting plastic translucent and/or advertising panels to balconies, banisters and stair railings, without using screws.
A third objective of the present invention is to provide devices, systems and methods of mounting plastic translucent and/or advertising panels to balconies, banisters and stair railings, without causing damage to underlying surfaces.
A fourth objective of the present invention is to provide devices, systems and methods of mounting plastic translucent and/or advertising panels to balconies, banisters and stair railings, without using cable ties.
A fifth objective of the present invention is to provide devices, systems and methods of mounting plastic translucent and/or advertising panels to balconies, banisters and stair railings, without having to punch holes in the panels.
A sixth objective of the present invention is to provide devices, systems and methods of mounting plastic translucent and/or advertising panels to balconies, banisters and stair railings, that is easy to both install and remove.
A seventh objective of the present invention is to provide devices, systems and methods of mounting plastic translucent and/or advertising panels to balconies, banisters and stair railings, that is aesthetically pleasing when installed without using unsightly mounting fasteners.
A barrier system for banisters, balconies and stair railings, includes a flexible panel having a generally rectangular configuration, a plurality of elongated strips with exterior surfaces having adhesive thereon, and a plurality of post clips, wherein the panel is attachable to posts that support railings on the banisters, balconies and stair railings, by positioning the elongated strips between portions of the panel and side surface portions of the post, and by clamping upper and lower edge portions of the panel to side portions of the posts by the post clips.
Each of the elongated strips can include a pair of strips sandwiched together having exterior surfaces with peel and stick tape, and interior facing magnetic surfaces;
Each of the post clips can include a clamp member having a configuration along a horizontal plane for clamping about the side portions of the posts, and a finger portion which extends perpendicular from a horizontal plane of the clamp member so that the finger portion presses against an exterior surface portion of the panel. The finger portion of the clips can include an S shape. Additionally, the finger portion can have a flat exterior face and an inner convex face.
The clamp member of each post clip can include two bendable flanges having outer ends which snap about the side portions of the post. The bendable flanges can have a spacing therebetween of approximately 0.8 inches. The bendable flanges can have a spacing therebetween of approximately 2 inches. Each of the bendable flanges can have snapable hook ends.
The clamp member can be a zip tie. The clamp member can include double sided tape. The clamp member can include a strip having hook and loop fasteners. The clamp member can include a rail clip strap with retaining strap on one end and a second end with a strap clip snap cutout. The clamp member can include a belt with buckle end for clamping about a perimeter surface of the post.
Each clamp member can include a pair of clamp members, and the finger is an elongated member having ends attached to each clamp member. Each of the clamp member pairs can include a rail clip strap with retaining strap on one end and a second end with a strap clip snap cutout.
The plastic panel can include a translucent plastic panel or colored panel with or without signage and indicia thereon.
A barrier system for banisters, balconies and stair railings, can include a flexible panel having a generally rectangular configuration, a plurality of elongated strips with exterior surfaces having adhesive thereon, each of the elongated strips includes a pair of strips sandwiched together having exterior surfaces with peel and stick tape, and interior facing magnetic surfaces, and a plurality of post clips, each of the post clips include a clamp member having a configuration along a horizontal plane for clamping about the side portions of the post and a finger portion which extends perpendicular from a horizontal plane of the clamp member, wherein the panel is attachable to posts that support railings on the banisters, balconies and stair railings, by positioning the elongated strips between portions of the panel and side surface portions of the post, and by clamping upper and lower edge portions of the panel to side portions of the posts by the post clips so that the finger portion presses against an exterior surface of the panel.
A method of protecting banisters, balconies and stair railings, can include the steps of providing a rectangular flexible plastic panel, providing a plurality of double sided tape strips, providing a plurality of attachable and detachable post clamps, attaching one side surface of the panel to surfaces of posts that support railings with the double sided tape strips, and clamping upper and lower edges of the panel to the posts by the post clamps.
The step of providing the plurality of double sided tape strips can include the step of providing each of the elongated strips with a pair of strips sandwiched together having exterior surfaces with peel and stick tape, and interior facing magnetic surfaces.
The step of providing the plurality of post clamps, can include the steps of providing a clamp member having a configuration along a horizontal plane for clamping about the side portions of the post and a finger portion which extends perpendicular from a horizontal plane of the clamp member, and pressing an outer surface portion of the panel with the finger portion.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a front view of an existing banister with post supported railing.
FIG. 2 is a front view of the banister of FIG. 11 with the novel barrier system installed.
FIG. 3 is an enlarged perspective partial view of the installed barrier system of FIG. 2 .
FIG. 4 is an enlarged perspective view of an 0.8″ rail clip for the installed barrier of FIG. 2 .
FIG. 5 is an enlarged perspective view of a 2″ rail clip for the installed barrier of FIG. 2 .
FIG. 6 is a rear perspective view of the installed barrier system of FIG. 3 .
FIG. 7 is a rear perspective view of the 0.8″ rail clip of FIG. 4 .
FIG. 8 is a rear perspective view of the installed 2″ rail clip of FIG. 5 .
FIG. 9 is an exploded front perspective view of barrier system ready to be installed.
FIG. 10 shows a partially rolled flexible plastic film barrier with magnet strips.
FIG. 11 shows the plastic film barrier of FIG. 10 unrolled and ready to be installed.
FIG. 12 is a top view of the 2″ snap on rail clip of FIGS. 5 and 8 .
FIG. 13 is a perspective view of the 2″ snap on rail clip of FIGS. 5 , 8 and 12 .
FIG. 14 is a front view of the 2″ snap on rail clip of FIGS. 5 , 8 , 12 and 13 .
FIG. 15 is a side view of the 2″ snap on rail clip of FIGS. 5 , 8 , and 12 - 14 .
FIG. 16 a top view of the 0.8″ snap on rail clip of FIGS. 4 , and 7 .
FIG. 17 is a perspective view of the 0.8″ snap on rail clip of FIGS. 4 , 7 and 16 .
FIG. 18 is a front view of the 0.8″ snap on rail clip of FIGS. 4 , 7 , 16 and 17 .
FIG. 19 is a side view of the 0.8″ snap on rail clip of FIGS. 4 , 7 , and 16 - 18 .
FIG. 20 is an exploded view of a rail clip being installed to a banister with a tie-on.
FIG. 21 shows the installed rail clip mounted to the post of the banister of FIG. 20 .
FIG. 22 is an exploded view of a rail clip being installed with hook/loop fasteners or double sided tape to a post of a banister.
FIG. 23 shows the installed rail clip mounted to the post of the banister of FIG. 22 .
FIG. 24 is an exploded view of a rail clip being installed with strap fasteners to a banister.
FIG. 25 shows the installed rail clip mounted to the post of the banister of FIG. 24 .
FIG. 26 is a top view of the rail clip used in FIGS. 20-25 .
FIG. 27 is a perspective view of the rail clip of FIGS. 20-26 .
FIG. 28 is a front view of the rail clip of FIGS. 20-27 .
FIG. 29 is a side view of the rail clip of FIGS. 20-28 .
FIG. 30 is a front perspective view of an installed strap rail clip.
FIG. 31 is a rear perspective view of rail clip of FIG. 30 with strap bar unfastened.
FIG. 32 is a rear perspective view of the rail clip of FIGS. 30-31 with strap bar fastened.
FIG. 33 is a top perspective view of rail clip of FIGS. 30-32 with strap rail clip fastened.
FIG. 34 is a top perspective view of the rail clip of FIGS. 30-33 with strap rail clip unfastened.
FIG. 35 is a rear perspective view of the rail clip of FIGS. 30-34 with strap rail clip fastened.
FIG. 36 is a rear perspective view of the rail clip of FIGS. 30-35 with strap rail clip unfastened.
FIG. 37 is a front perspective exploded view of a barrier system being installed with full length post clamp.
FIG. 38 is an enlarged view of a top of a full length post clamp ready for installation.
FIG. 39 is a front perspective view of the barrier system of FIG. 37 installed on a banister.
FIG. 40 is an enlarged view of a top of the installed full length post clamp installed.
FIG. 41 is a rear perspective view of full length post clamp with open clips.
FIG. 42 is a rear perspective view of the full length clamp of FIG. 41 with clips closed.
FIG. 43 is a front perspective view of the full length clamp of FIG. 42 with clips closed.
FIG. 44 is a perspective view of the barrier system of the preceding figures installed on an existing banister supported to the wall with magnetic strips.
FIG. 45 is an exploded view of the end of the barrier with magnetic strip.
FIG. 46 is an exploded perspective view of a clip with belt buckle strap ready to be used to install a barrier to a post of a banister.
FIG. 47 is a perspective view of the buckle strap clip of FIG. 46 installed to a banister.
FIG. 48 is a top view of another snap on rail clip having a finger portion with a generally flat exterior face and a convex protruding inner face.
FIG. 49 is a front view of the clip of FIG. 48 .
FIG. 50 is a side view of the clip of FIG. 48 .
FIG. 51 is a perspective view of the clip of FIG. 48 .
FIG. 52 is a top view of another strap rail clip.
FIG. 53 is a front view of the clip of FIG. 52 .
FIG. 54 is a side view of the clip of FIG. 52 .
FIG. 55 is a perspective view of the clip of FIG. 52 .
FIG. 56 is a perspective view of the clip of FIG. 55 with a hook and loop strap installed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
A list of the components used with the invention will now be described.
1 . barrier system 10 . Flexible plastic film barrier panel. Can be transparent or colored opaque. 20 . 2″ snap on rail clip. 30 . 8″ snap on rail clip. 40 . Existing banister with post supported ends. 45 . railing 50 . 2″ banister post. 60 . 8″ banister post. 70 . Side wall. 80 . Deck. 90 . Logo, trademark, or other advertising printed onto film barrier. 100 . Seam between film barrier panels. 110 . 8″ clamping finger. 120 . 2″ clamping finger. 130 . 2″ clamp retaining snap. 140 . 8″ clamp retaining snap. 150 . 1″ wide self-adhesive magnet strip adhered to 2″ rail post. 160 . ½″ wide self-adhesive magnet strip adhered to 0.8″ rail post. 170 . 1″ wide self-adhesive magnet strip adhered to plastic film barrier panel. 180 . ½″ wide self-adhesive magnet strip adhered to plastic film barrier panel. 190 . hook and loop, double sided tape, or zip-tie (VDZ) mounted rail clip. 200 . hook and loop or double sided tape. 210 . VDZ clamping finger 220 . VDZ mounting surface for double sided tape or self-adhesive Velcro. 230 . Pass-through hole for zip ties or hook and loop strap. 240 . Zip tie. 250 . Existing banister with wall supported ends. 260 . 1″ wide self-adhesive magnet strip adhered to side wall. 270 . 1″ wide self-adhesive magnet strip adhered to folded panel flange. 280 . Flange folded on end of flexible plastic film to interface to side wall. 290 . hook and loop strap. 300 . 2″ strap rail clip. 310 . Strap clip retaining snap. 320 . Strap clip hinged strap bar. 330 . Strap clip snap cutout. 340 . Plastic live hinge. 350 . Full length clamp with strap rail clips incorporated into each end. 360 . Full length clamping bar clamps the full length of the seam between film barriers. 370 . Buckle strap. 380 . Buckle. 390 . Alternate snap on rail clip. 392 . front flat face of finger 394 . inner convex face of finger 396 . side leg with snap end(hook end) 398 . side leg with snap end(hook end) 400 . Alternate hook and mount clip. 402 . head end 403 . side slot for strap 404 . front flat face of finger 406 . inner convex face of finger
FIG. 1 is a front view of an existing banister 40 with posts 50 / 60 that support railing 45 on a deck 80 with side walls 70 . FIG. 2 is a front view of the banister 40 of FIG. 11 with the novel barrier system 1 installed. FIG. 3 is an enlarged perspective partial view of the installed barrier system 1 of FIG. 2 . FIG. 4 is an enlarged perspective view of an 0.8″ rail clip 30 for the installed barrier system 1 of FIG. 2 . FIG. 5 is an enlarged perspective view of a 2″ rail clip 20 for the installed barrier of FIG. 2 . FIG. 6 is a rear perspective view of the installed barrier system 1 of FIG. 3 . FIG. 7 is a rear perspective view of the 0.8″ rail clip 30 of FIG. 4 . FIG. 8 is a rear perspective view of the installed 2″ rail clip 20 of FIG. 5 . FIG. 9 is an exploded front perspective view of barrier system 1 ready to be installed.
FIG. 10 shows a partially rolled flexible plastic film barrier 10 with magnet strips 170 , 180 that can be adhered to the plastic barrier panel 10 . FIG. 11 shows the plastic film barrier 10 of FIG. 10 unrolled and ready to be installed.
FIG. 12 is a top view of the 2″ snap on rail clip of FIGS. 5 and 8 . FIG. 13 is a perspective view of the 2″ snap on rail clip 20 of FIGS. 5 , 8 and 12 . FIG. 14 is a front view of the 2″ snap on rail clip 20 of FIGS. 5 , 8 , 12 and 13 . FIG. 15 is a side view of the 2″ snap on rail clip 20 of FIGS. 5 , 8 , and 12 - 14 .
FIG. 16 a top view of the 0.8″ snap on rail clip 30 of FIGS. 4 , and 7 . FIG. 17 is a perspective view of the 0.8″ snap on rail clip 30 of FIGS. 4 , 7 and 16 . FIG. 18 is a front view of the 0.8″ snap on rail clip 30 of FIGS. 4 , 7 , 16 and 17 . FIG. 19 is a side view of the 0.8″ snap on rail clip 30 of FIGS. 4 , 7 , and 16 - 18 .
Referring to FIGS. 1-10 , the novel barrier system 1 can be installed to cover the inner sides of posts 50 of an existing banister 40 . A flexible semi-rigid plastic film barrier panel 10 can be transparent and/or colored opaque. Additionally, the panel 10 can have indicia thereon, such as but not limited to business signage, messages, and the like. The panel can have various thicknesses, such as but not limited to being several mils thick to being approximately 14 to approximately 16 mils thick. The panels can be treated for UV(ultra violet rays) exposure.
The invention can use double sided magnetic tape, such as the double side magnetic tape described in U.S. Patent Application Publication 2001/0055666 to Lee et al., which is incorporated by reference. The invention can use either or both 1″ wide double sided self-adhesive magnetic strips 170 , and/or ½″ wide double sided self-adhesive magnetic strips 180 .
Before installation, the installer can cut desired sections of the flexible plastic film barrier panel 10 from a roll.
The 1″ wide self-adhesive magnetic strips 170 can be adhered to one side of the flexible plastic film barrier in parallel arrangements with one another, which can be spaced apart to overlay the inner surfaces of the 2″ banister posts 50 .
Additionally, the ½″ wide self-adhesive magnetic strips 180 can be adhered to one side of the flexible plastic film barrier in parallel arrangements with one another, which can be spaced apart to overlay the inner surfaces of the 0.8″ banister posts 60 .
The 1″ wide self-adhesive magnetic strips 150 can be adhered to the inner surfaces of the 2″ banister posts 50 .
Additionally, the ½″ wide self-adhesive magnetic strips 160 can be adhered to the inner surfaces of the 0.8″ banister posts 60 .
The installer can position to orient the selected sheet of panel 10 so that the exposed magnetic surfaces of strips 170 on panel 10 attach to the exposed magnetic surfaces of strips 150 on posts 50 . Similarly, the exposed magnetic surfaces of strips 180 on panel 10 attach to the exposed magnetic surfaces of the strips 160 on posts 60 .
Referring to FIGS. 1-19 , the mounted sheet panels 10 can be oriented end to end with one another on the posts 50 , 60 of the banister 40 so that any vertical seams 100 overlay a mid portion of the larger 2″ banister posts 50 . Referring to FIGS. 5 , 6 , 8 , 9 , 12 - 15 , the 2″ snap on rail clips 20 can have side legs each with hooked ends 130 which allow the clips 20 to snap about the posts 50 . The installer can orient the clips 20 so that the S shaped 2″ clamping fingers 120 on upper and lower placed clips 20 overlays against upper and lower seam edges 100 of the side by side panels 10 .
Referring to FIGS. 4 , 6 , 7 , 9 , and 16 - 19 , the 0.8″ clips 30 can have side legs each with hooked ends 140 which allow the clips 30 to snap about the posts 60 . The installer can orient the clips 30 so that the S shaped 0.8″ clamping fingers 110 on upper and lower placed clips 30 can hold top and bottom edges of the panel 10 against the posts 60 .
FIG. 20 is an exploded view of another type of rail clip 190 having a generally upside down J shape with the leg portion also having a generally S shape. The hook portion of the J can be attached to a post 50 / 60 by one or two zip ties 240 that each can be inserted between the hook and S shape portions of the clip and adjustably tightened about the posts 50 / 60 . FIG. 21 shows the installed rail clip 190 mounted to the post 50 / 60 of the banister 40 of FIG. 20 .
FIG. 22 is an exploded view of a rail clip 190 being installed with interlocking hook/loop fasteners 200 and/or double sided tape 200 to a post 50 / 60 of a banister 40 . The installer can attach one side of the hook and loop fastener or double sided tape to the post 50 / 60 , and the mating side of the hook and loop fastener or double sided tape to the outer surface of the hook portion of the clip 190 . FIG. 23 shows the installed rail clip 190 mounted to the post 50 / 60 of the banister 40 of FIG. 22 .
FIG. 24 is an exploded view of a rail clip 190 being installed with strap fasteners 290 that each can be inserted between the hook and S shape portions of the clip 190 and adjustably tightened about the posts 50 / 60 . The strap fasteners 290 can be strips with hook and loop fasteners along the surfaces. FIG. 25 shows the installed rail clip 190 mounted to the post of the banister 40 of FIG. 24 .
FIG. 26 is a top view of the rail clip 190 used in FIGS. 20-25 . FIG. 27 is a perspective view of the rail clip 190 of FIGS. 20-26 . FIG. 28 is a front view of the rail clip 190 of FIGS. 20-27 . FIG. 29 is a side view of the rail clip 190 of FIGS. 20-28 .
Referring to FIGS. 26-29 , the rail clip 190 can include a S shaped clamping finger 210 with an upper end attached to a hook edge 220 having an exterior mounting surfaces for mounting the double sided tape and/or double sided hook and loop fasteners thereon. The hook edge 220 can also have a pass-through 230 for allowing the zip tie(s) 240 to pass therethrough.
FIG. 30 is a front perspective view of another installed strap rail clip 300 . FIG. 31 is a rear perspective view of rail clip 300 of FIG. 30 with strap bar 320 attached to hinge 40 in an unfastened position. FIG. 32 is a rear perspective view of the rail clip 300 of FIGS. 30-31 with strap bar 320 fastened. FIG. 33 is a top perspective view of rail clip 300 of FIGS. 30-32 with strap rail clip 300 fastened about a post 50 / 60 . FIG. 34 is a top perspective view of the rail clip 300 of FIGS. 30-33 with strap rail clip bar 320 unfastened. FIG. 35 is a rear perspective view of the rail clip 300 of FIGS. 30-34 with strap rail clip bar 320 fastened. FIG. 36 is a rear perspective view of the rail clip 300 of FIGS. 30-35 with strap rail clip bar 320 unfastened.
Referring to FIGS. 30-36 , clip 300 can have a front side with an S shaped clamping finger 120 with rear sides having a strap clip hinged strap bar 320 with an outer end that can bend about the rear of a post 50 / 60 , with a strap clip snap cutout 330 thereon. Opposite strap portion of clip 300 can have an end with a snap clip retaining snap 310 that can snapably attach into the snap cutout 330 locking the clip 300 to the post 50 / 60 .
FIG. 37 is a front perspective exploded view of a barrier system 1 being installed with full length post clamp 350 . FIG. 38 is an enlarged view of a top of a full length post clamp 350 ready for installation. FIG. 39 is a front perspective view of the barrier system 1 of FIG. 37 installed on a banister 40 . FIG. 40 is an enlarged view of a top of the installed full length post clamp 350 installed on a post 50 / 60 . FIG. 41 is a rear perspective view of full length post clamp 350 with open clips. FIG. 42 is a rear perspective view of the full length clamp 350 of FIG. 41 with clips closed. FIG. 43 is a front perspective view of the full length clamp 350 of FIG. 42 with clips closed.
Referring to FIGS. 37-43 , the full length clamp 350 can have a full length clamping bar portion 360 with snap clip retaining snap 310 , strap clip hinged strap bar 320 , strap clip snap cutout 330 and hinge 340 , which function and install as previously described about the posts 50 both above and below the panel 10 . The elongated bar portion 360 can also be attached to post 50 using any of the previously described clips. The elongated bar portion 360 allows for the seams 100 between the panels to be more completely covered and protected from peeling off.
FIG. 44 is a perspective view of the barrier system 1 of the preceding figures installed on an existing banister 250 whose railings are attached directly to a wall. FIG. 45 is an exploded view of the end of the barrier 10 with magnetic strip 260 thereon. The outer side edge 280 of the panel 10 can be folded to form a flange in order to interface with a fall surface. A 1″ wide self-adhesive magnetic strip can be adhered to an outer surface of the flange 280 . Another 1″ wide self-adhesive magnetic strip 260 can be adhered to the side wall, so that both magnetic strips 260 , 270 attach to one another.
FIG. 46 is an exploded perspective view of a clip 190 previously described with a belt buckle strap 370 , 380 ready to be used to install a barrier 10 to a post 50 of a banister 40 . FIG. 47 is a perspective view of the buckle strap clip 370 , 380 of FIG. 46 installed to a post 50 of banister 40 . The buckle portion 380 allows for the clip 190 to be adjustably tightened about the post 50 / 60 .
FIG. 48 is a top view of another snap on rail clip 390 having a finger portion 392 , 394 with a generally flat exterior face 392 and a convex protruding inner face 394 . FIG. 49 is a front view of the clip 390 of FIG. 48 . FIG. 50 is a side view of the clip 390 of FIG. 48 . FIG. 51 is a perspective view of the clip 390 of FIG. 48 . This rail clip 390 can be an alternate snap on rail clip to the rail clip shown and described in relation to FIGS. 12-19 .
The snap on rail clip 390 can include a front flat face of finger 392 , and an inner convex face of finger 394 with raised portion that presses against an upper or lower edge portion of the installed panel 10 or against a seam 100 in the installed panel(s) 10 . Clip 390 can function similarly to the clips 20 , 30 by having both a first side leg with snap end(hook end) 396 , and a second side leg with snap end(hook end) 398 , wherein the legs snap about sides of posts 50 , 60 shown in the previous figures.
FIG. 52 is a top view of another strap rail clip 400 . FIG. 53 is a front view of the clip 400 of FIG. 52 . FIG. 54 is a side view of the clip 400 of FIG. 52 . FIG. 55 is a perspective view of the clip 400 of FIG. 52 . FIG. 56 is a perspective view of the clip 400 of FIG. 55 with a hook and loop strap 290 installed.
This alternate clip 400 includes a head end 402 with side slot 403 that allows for a strap 290 , such as a hook and loop fastener strap to be inserted therethrough. Clip 400 includes a finger portion with a front flat face 404 and an inner facing edge convex curved edge 406 that can press against an exterior portion of a panel 10 or a seam 100 between panel(s) 10 . The clip 400 attached to posts 40 / 60 similar to the clip 190 shown and described in reference to FIGS. 24-29 .
The clips can be made from plastic, metal, combinations thereof, and the like.
Although dimensions for the post clips and tape strips are referenced above, the invention clip sizes and tape strips can vary depending upon the different diameter posts.
Although the double sided tape described above, uses magnets, the invention include double sided tape without magnets. Additionally, the double sided tape can include hook and loop fasteners, such as mushroom headed fasteners.
While the invention is described as a barrier for protecting pets and children, the barrier invention can be used for storm protection to prevent air, rain, snow, and the like, from passing through the openings between posts underneath railings.
The novel barrier can be easily disassembled and put away when not being used. The invention can be installed by professionals, consumers, and/or be packaged in kit forms with the components in a package.
While the invention is described for use with balconies, banisters and stair railings having posts, the invention can be used to cover openings between vertical posts in other applications, such as but not limited to cribs, bassinets, and the like. Still furthermore, the protective barrier invention can be used to cover other openings, such as but not limited to doorways, windows, entrances to stairs, and any other type of opening.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Devices, systems and methods of mounting plastic translucent panels and/or colored panels and/or advertising panels to balconies, banisters and stair railings using magnetic fasteners and clips, to protect pets and small children. The panels can be attached by a plurality of strips of double sided magnetic tape to the posts of the banister. Snapable clips can be attached to the posts above and below the panel to further hold the panel to the banister. | 4 |
RELATED APPLICATION DATA
This application is related to the application Ser. No. 08/873,079 entitled “Portable Acoustic Interface For Remote Access To Automatic Speech/Speaker Recognition Server”, which is commonly assigned and is filed concurrently with the present invention.
This is a continuation of application Ser. No. 09/275,592, filed Mar. 24, 1999, now U.S. Pat. No. 6,161,090, which is continuation of U.S. application Ser. No. 08/871,784, filed Jun. 11, 1997, now U.S. Pat. No. 5,897,616. This application is related to the application (Docket Number YO997-136) entitled “Portable Acoustic Interface For Remote Access To Automatic Speech/Speaker Recognition Server”, Ser. No. 08/873,079 filed Jun. 11, 1997, now U.S. Pat. No. 5,953,700, which is commonly assigned and is filed concurrently with the present invention, and to copending application Ser. No. 09/548,016 filed Apr. 12, 2000, which is itself a continuation of U.S. application Ser. No. 08/788,471 filed Jan. 28, 1997, now U.S. Pat. No. 6,073,101.
BACKGROUND OF THE INVENTION
The present invention relates to methods and apparatus for providing security with respect to user access of services and/or facilities and, more particularly, to methods and apparatus for providing same employing automatic speech recognition, text-independent speaker identification, natural language understanding techniques and additional dynamic and static features.
In many instances, it is necessary to verify that an individual requesting access to a service or a facility is in fact authorized to access the service or facility. For example, such services may include banking services, telephone services, or home video provision services, while the facilities may be, for example, banks, computer systems, or database systems. In such situations, users typically have to write down, type or key in (e.g., on a keyboard) certain information in order to send an order, make a request, obtain a service, perform a transaction or transmit a message.
Verification or authentication of a customer prior to obtaining access to such services or facilities typically relies essentially on the customer's knowledge of passwords or personal identification numbers (PINs) or by the customer interfacing with a remote operator who verifies the customer's knowledge of information such as name, address, social security number, city or date of birth, mother's maiden name, etc. In some special transactions, handwriting recognition or signature verification is also used.
However, such conventional user verification techniques present many drawbacks. First, information typically used to verify a user's identity may be easily obtained. Any perpetrator who is reasonably prepared to commit fraud usually finds it easy to obtain such personal information such as a social security number, mother's maiden name or date of birth of his intended target. Regarding security measures for more complex knowledge-based systems which require passwords, PINs or knowledge of the last transaction/message provided during the previous service, such measures are also not reliable mainly because the user is usually unable to remember this information or because many users write the information down thus making the fraudulent perpetrator's job even easier. For instance, it is known that the many unwitting users actually write their PINs on the back of their ATM or smart card.
The shortcomings inherent with the above-discussed security measures have prompted an increasing interest in biometric security technology, i.e., verifying a person's identity by personal biological characteristics. Several biometric approaches are known. However, one disadvantage of biometric approaches, with the exception of voice-based verification, is that they are expensive and cumbersome to implement. This is particularly true for security measures involved in remote transactions, such as internet-based or telephone-based transaction systems.
Voice-based verification systems are especially useful when it is necessary to identify a user who is requesting telephone access to a service/facility but whose telephone is not equipped with the particular pushbutton capability that would allow him to electronically send his identification password. Such existing systems which employ voice-based verification utilize only the acoustic characteristics of the utterances spoken by the user. As a result, existing voice identification methods, e.g., such as is disclosed in the article: S. Furui, “An Overview of Speaker Recognition”, Automatic Speech and Speaker Recognition, Advanced Topics, Kluwer Academic Publisher, edited by C. Lee, F. Soong and K. Paliwal, cannot guarantee a reasonably accurate or fast identification particularly when the user is calling from a noisy environment or when the user must be identified from among a very large database of speakers (e.g., several million voters). Further, such existing systems are often unable to attain the level of security expected by most service providers. Still further, even when existing voice verification techniques are applied under constrained conditions, whenever the constraints are modified as is required from time to time, verification accuracy becomes unpredictable. Indeed, at the stage of development of the prior art, it is clear that the understanding of the properties of voice prints over large populations, especially over telephone (i.e., land or cellular, analog or digital, with or without speakerphones, with or without background noise, etc.), is not fully mastered.
Furthermore, most of the existing voice verification systems are text-dependent or text-prompted which means that the system knows the script of the utterance repeated by the user once the identify claim is made. In fact in some systems, the identity claim is often itself part of the tested utterance; however, this does not change in any significant way the limitations of the conventional approaches. For example, a text-dependent system cannot prevent an intruder from using a pre-recorded tape with a particular speaker's answers recorded thereon in order to breach the system.
Text-independent speaker recognition, as the technology used in the embodiments presented in the disclosure of U.S. Ser. No. 08/788,471, overcomes many disadvantages of the text-dependent speaker recognition approach discussed above. But there are still several issues which exist with respect to text-independent speaker recognition, in and of itself. In many applications, text-independent speaker recognition requires a fast and accurate identification of the identity of a user from among a large number of other prospective users. This problem is especially acute when thousands of users must be processed simultaneously within a short time period and their identities have to be verified from a database that stores millions of user's prototype voices.
In order to restrict the number of prospective users to be considered by a speech recognition. device and to speed up the recognition process, it has been suggested to use a “fast match” technique on a speaker, as disclosed in the patent application Ser. No. 08/851,982 entitled, “Speaker Recognition Over Large Population with Combined Fast and Detailed Matches”, filed on May 6, 1997. While this procedure is significantly faster than a “detailed match” speaker recognition technique, it still requires processing of acoustic prototypes for each user in a database. Such a procedure can still be relatively time consuming and may generate a large list of candidate speakers that are too extensive to be processed by the recognition device.
Accordingly, among other things, it would be advantageous to utilize a language model factor similar to what is used in a speech recognition environment, such factor serving to significantly reduce the size of fast match lists and speed up the procedure for selecting candidate speakers (users) from a database. By way of analogy, a fast match technique employed in the speech recognition environment is disclosed in the article by L. R. Bahl et al., “A Fast Approximate Acoustic Match for Large Vocabulary Speech Recognition”, IEEE Trans. Speech and Audio Proc., Vol. 1, pg. 59-67 (1993).
SUMMARY OF THE INVENTION
It is an object of the present invention to provide methods and apparatus for providing secure access to services and/or facilities which preferably utilize random questioning, automatic speech recognition (ASR) and text-independent speaker recognition techniques. Also, indicia contained in spoken utterances provided by the speaker may serve as additional information about the speaker which may be used throughout a variety of steps of the invention.
In one aspect of the present invention, a method of controlling access of a speaker to one of a service and a facility comprises the steps of: (a) receiving first spoken utterances of the speaker, the first spoken utterances containing indicia of the speaker; (b) decoding the first spoken utterances; (c) accessing a database corresponding to the decoded first spoken utterances, the database containing information attributable to a speaker candidate having indicia substantially similar to the speaker; (d) querying the speaker with at least one random (but questions could be non-random) question (but preferably more than one random question) based on the information contained in the accessed database; (e) receiving second spoken utterances of the speaker, the second spoken utterances being representative of at least one answer to the at least one random question; (f) decoding the second spoken utterances; (g) verifying the accuracy of the decoded answer against the information contained in the accessed database serving as the basis for the question; (h) taking a voice sample from the utterances of the speaker and processing the voice sample against an acoustic model attributable to the speaker candidate; (i) generating a score corresponding to the accuracy of the decoded answer and the closeness of the match between the voice sample and the model; and (j) comparing the score to a predetermined threshold value and if the score is one of substantially equivalent to and above the threshold value, then permitting speaker access to one of the service and the facility. If the score does not fall within the above preferred range, then access may be denied to the speaker, the process may be repeated in order to obtain a new score, or a system provider may decide on another appropriate course of action.
In a first embodiment, the indicia may include identifying indicia, such as a name, address, customer number, etc., from which the identity claim may be made. However, in another embodiment, the identity claim may have already been made by the potential user keying in (or card swiping) a customer number or social security number, for example, in which case the indicia includes verifying indicia in order to aid in the verification of the identity claim. Also, the indicia may serve as additional information about the user which may serve as static and/or dynamic parameters in building or updating the user's acoustic model.
In another aspect of the present invention, a method of controlling access of a speaker to one of a service and a facility from among a multiplicity of speaker candidates comprises the steps of: (a) receiving first spoken utterances of the speaker, the first spoken utterances containing indicia of the speaker; (b) decoding the first spoken utterances; (c) generating a sub-list of speaker candidates that substantially match the speakers decoded spoken utterances; (d) activating databases respectively corresponding to the speaker candidates in the sub-list, the databases containing information respectively attributable to the speaker candidates; (e) performing a voice classification analysis on voice characteristics of the speaker; (f) eliminating speaker candidates who do not substantially match these characteristics; (g) querying the speaker with at least one question that is relevant to the information in the databases of speaker candidates remaining after the step (f); (h) further eliminating speaker candidates based on the accuracy of the answer provided by the speaker in response to the at least one question; (i) further performing the voice classification analysis on the voice characteristics from the answer provided by the speaker; (j) still further eliminating speaker candidates who do not substantially match these characteristics; and (k) iteratively repeating steps (g) through (j) until one of one speaker candidate and no speaker candidates remain, if one speaker candidate remains then permitting the speaker access and if no speaker candidate remains then denying the speaker access. Of course, it is possible to repeat the entire process if no speaker candidate is chosen or a system provider may choose another appropriate course of action.
Again, as mentioned above, the method of the invention may be used for identification and/or verification without any explicit identification given by the user (e.g., name). By checking the type of request made by the user, using additional information, if provided, and by using the acoustic match, discussed above, user identification may be established. Further, by using the random questions in addition to the acoustic identification, a more accurate identification is achieved in almost any type of environment.
It is therefore an object of the invention to provide apparatus and methods which: use external information to build user's models; extract non-feature-based information from the acoustic properties of the speech to build user's models; extract non-acoustic information from the speech to build user's models; drives the conversations to request specific information; decodes and: understands the answers to these questions; compares the answers to information stored in a database; and build user's model on answers to the questions.
The resulting system is a combination of technology: text-independent speaker recognition, speech recognition and natural language understanding. It is also possible to add new questions, decode and understand the answer and add this question in the pool of the random questions for next access request by the same user.
It is also to be appreciated that the methods and apparatus described herein use voice prints (speaker recognition), speech recognition, natural language understanding, acoustic and content analysis to build a new biometric. Such a speech biometric contains acoustic information, semantic information, static and dynamic information, as will be explained, and is also a knowledge based system. However, while the invention utilizes knowledge known by the user and knowledge acquired by the speech recognition engine (e.g., speech rate, accent, preferred vocabulary, preferred requests), the combination thereof provides advantages much greater than the advantages respectively associated with each individual aspect. Such a formation of this unique speech biometric including voice prints and knowledge based systems has, prior to this invention, been unknown since the two concepts have previously been considered substantially mutually exclusive concepts.
The overall system provides a security level with an arbitrary level of security with speech and speaker recognition technology and natural language understanding. This global architecture has the advantage of being universal and adaptable to substantially any situation. The complete transaction is monitored so that possible problems can be detected in using this large amount of data and flags are raised for further processing for action by the service provider.
These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart/block diagram illustrating the functional interconnection between components of the invention;
FIG. 2 is a flow chart/block diagram further illustrating components of the invention;
FIG. 3 is a flow chart/block diagram illustrating an iterative procedure performed according to the invention;
FIG. 4 is a block diagram illustrating a user database according to the invention; and
FIG. 5 is a flow chart/block diagram illustrating the generation of a user model according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring initially to FIG. 1, a flow chart/block diagram of the basic components of the invention is shown. The invention employs a unique combination of random questions, automatic speech recognition (ASR) and text-independent speaker recognition to provide a significant improvement in secure access to services and/or facilities (as discussed previously) requiring security measures. Specifically, a user (block 12 ) requesting access to a service/facility is subjected to a security system 10 employing a combination of random questions, ASR and text-independent speaker recognition (block 14 ) via an iterative process (loop 16 ) whereby the security system 10 utilizes user databases of non-acoustic information (block 18 ) and/or an acoustic user model (block 20 ) to perform the verification/identification of the user 12 . These components and their specific interaction will be explained below in the context of the remaining figures.
It is to be understood that the components described herein in accordance with the invention may be implemented in hardware, software, or a combination thereof. Preferably, the invention is implemented in software in the form of functional software modules on an appropriately programmed general purpose digital computer or computers. The actual location of the computer system implementing the invention is not critical to the invention; however, in an application where the user is requesting remote access via telephone, the invention or portions thereof may reside at the service/facility location or some location remote thereto. Further, the invention may be implemented in an internet environment in which case various portions of the invention may reside at the user's location and/or the service providers location.
Referring now to FIG. 2, one embodiment of the invention, illustrated via a flow chart/block diagram, is shown. It is to be understood that same or similar components illustrated throughout the figures are designated with the same reference numeral, A potential user 12 of the service/facility performs the following operation in cooperation with security system 10 in order to gain access to the service/facility. The user 12 calls a central server 22 via link 24 . The user 12 identifies himself via his name, for example, and requests access to the service/facility. The central server 22 then performs the following operations. The server 22 submits the utterance of the user's name and request to automatic speech recognizer (ASR) 28 via link 26 which decodes the utterance and submits the decoded name and request back to server 22 . It is to be appreciated that, while preferable, the name of the speaker is not mandatory in establishing the identity claim. The identity claim may be made from other information provided by the speaker or voice characteristics, as explained herein. Also, the identity claim may be established by the user keying in or using a magnetic strip card to provide an identification number. The server 22 then accesses a database (which is part of the user databases 18 ) via link 30 corresponding to the user (candidate) identified during the identification claim. As will be explained, the user. database contains information specific to that particular user. Also, an acoustic model 20 pertaining to that user (as will be explained) is selected from the user's database through link 32 and provided to the central server 22 via link 34 .
Next, utilizing the specific information from the identified user's database, the server 22 generates a random question (or multiple random questions) for the user via link 36 . The user answers the random question(s) which is sent back to the server 22 via link 38 . It should be understood that links 24 , 36 and 38 are preferably provided over a single communication path which may be hardwired (e.g. PSTN) or wireless (e.g. cellular). The separation of links is meant to illustrate functionality rather than physical implementation.
The central server 22 receives the user's answer and processes it through ASR 28 . After decoding the answer, ASR 28 passes the decoded answer to a semantic analyzer 40 via link 42 . The semantic analyzer 40 analyzes the answer to determine if the answer is correct, or not, in accordance with the information in the user's database. The result of the semantic analyzer 40 is sent to a score estimator 44 via link 46 where a partial score associated with the answer received from the user is generated. It should be understood that the lack of a “perfect” partial score does not necessarily indicate an incorrect answer from the user due to the fact that known speech recognition processes, such as employed by ASR 28 , have acceptable recognition error rates associated therewith and, thus, while the actual answer is correct, the decoded answer may be close enough to satisfy the semantic analyzer 40 . Also, it is to be understood that some speech recognition and natural language understanding techniques may have recognition and/or understanding errors associated therewith such that, as a result, they do not correctly recognize and/or understand the answer provided by the speaker. Hence, in such cases, it is preferred that more than one random question be asked prior to making a decision to permit or deny access to the speaker. Links 46 , 48 and 50 from the score estimator 44 go back to the central server 22 to indicate whether the answer was correct, not correct, or for some reason (e.g., ASR could not properly decode the response), the answer was not understood and the answer should be repeated by the user 12 . The question and answer process between the user 12 and the central server 22 may continue for as many iterations as are desired to substantially ensure that the potential user is the user associated with the subject user database.
Substantially simultaneous with the spoken utterances provided by the user 12 , the central server 22 may process a user voice sample, for example, from the initial dialog from the potential user and/or from the answer or answers uttered by the potential user, through a text-independent speaker recognition module 52 via link 54 in order to verify (confirm) the user's identity. The module 52 utilizes the user model previously built (as will be explained in the context of FIG. 5) and which is presented to module 52 from user model 20 via link 51 . It is to be appreciated that such speaker recognition process of module 52 is preferably implemented by default, regardless of the partial score(s) achieved in the question/answer phase, in order to provide an additional measure of security with regard to service/facility access. The voice sample is processed against the user model and another partial score is generated by the score estimator 44 . Based on a comparison of a combination of the partial scores (from the question/answer phase and the background speaker verification provided by module 52 ) versus a predetermined threshold value, the central server 22 decides whether or not to permit access to the service/facility to the user 12 . If the combined score is above or within an acceptable predetermined range of the threshold value, the central server 22 may permit access, else the server may decide to deny access completely or merely repeat the process. Further, a service provider may decide to take other appropriate security actions.
The user model 20 may also be operatively coupled to the central server 22 (link 34 ), the semantic analyzer 40 (link 53 ), the score estimator 44 (link 56 ) and the ASR 28 (link 55 ) in order to provide a data path therebetween for the processes, to be further explained, performed by each module. Link 58 between the text-independent speaker recognition module 52 and the score estimator 44 is preferably provided in order to permit the module 52 to report the results of the voice sample/model comparison to the estimator 44 .
Also, it is to be understood that because the components of the invention described herein are preferably implemented as software modules, the actual links shown in the figures may differ depending on the manner in which the invention is programmed.
It is to be appreciated that portions of the information in each database and the user models may be built by a pre-enrollment process. This may be accomplished in a variety of ways. The speaker may call into the system and, after making an identity claim, the system asks questions and uses the answers to build acoustic and non-acoustic models and to improve the models throughout the entire interaction and during future interactions. Also, the user may provide information in advance (pre-enrollment) through processes such as mailing back a completed informational form with similar questions as asked during enrollment over the phone. Then, an operator manually inputs the information specific to the user into the system. Alternatively, the user may interact with a human operator who asks questions and then inputs answers to questions into the system. Still further, the user may complete a web (internet) question/answer form, or use e-mail, or answer questions from an IVR (Integrated Voice Response) system. Also, it is to be appreciated that the questions may preferably be relatively simple (e.g., what is your favorite color?) or more complex, depending on the application. The simpler the question, the more likely it is that the actual user will not be denied access simply because he forgot his answers.
Furthermore, because of the fact that text-independent speaker recognition is performed in the background and the questions are random in nature and the entire process is monitored throughout the dialog, even frauders using tape recorders or speech synthesizers cannot fool the system of the invention as such fraudulent processes cannot handle the random questions and/or the dialog in real-time. Still further, for a frauder to know the answers to all the questions will not help gain access to the service or facility, since if the frauder has a different speech rate or voice print, for example, then the identification and verification claim will fail. For these reasons, the actual user is encouraged to answer with a natural full sentence, that is, to establish a full dialog.
It is further to be understood that the system of the invention is capable of building more questions, either by learning about the user or, after identifying the user, asking new questions and using the answers (which are transcribed and understood) as the expected answers to future random questions.
Accordingly, it is to be appreciated that the invention can build databases and models both automatically and manually. Automatic enrollment is performed by obtaining the name, address and whatever other identification tag that the service/facility desires and then building, from scratch, models and compiling data usable for future identification or verification. Beyond the ability to self-enroll users, the system of the invention provides the ability to automatically adapt, improve or modify its authentication processes. Still further, the automatic nature of the invention permits the building of a user profile for any purpose including the possibility of having other self-enrolling, self-validating and/or self-updating biometrics (e.g., face patterns for face recognition, iris recognition, etc.). Thus, it is possible to combine biometrics (speech, voiceprint) in order to have self-enrolling biometrics. Self-validation is also provided such that whenever a score associated with the biometric match is poor, the present invention may be used to still admit the person but also to correct the models on the assumption that they are outdated.
It is to be appreciated that several variations to the above-described security access process are possible. For example, if a caller calls the central server 22 for the first time and the system has a database of information pertaining to the caller but does not have an acoustic model set up for that caller, the following procedure may be performed. The central server 22 asks a plurality of questions from the database, the number of questions depending upon the known average error rate associated with ASR 28 and semantic analyzer 40 . Then, based only on the scores achieved by the answers received to the questions, the server 22 makes a determination whether or not to permit access to the caller. However, the system collects voice samples from the caller's answers to the plurality of questions and builds a user voice model (e.g., user model 20 ) therefrom. Accordingly, the next time the caller calls, the server 22 need ask only a few random questions from the database and, in addition, use the text-independent speaker recognition module 52 along with the new user model to verify his identity, as explained above.
Many ways for communicating the random questions to the user may be envisioned by one of ordinary skill in the art. For instance, if the user is attempting to access the service/facility through a web page, the questions may be presented in text form. If access is attempted over a telephone line, the questions may be asked via a voice synthesizer, a pre-recorded tape or a human operator. The actual method of asking the questions is not critical to the invention. Alternatively, it is to be appreciated that at least a portion of the answers provided by the potential user may be in a form other than speech, i.e., text format, keyed-in information, etc.
A further variation to the above-described system includes an embodiment wherein the inventive security system is implemented in a user's personal computer (at his home or office) to which the user seeks access. In such a scenario, a module substantially equivalent to the central server module may use such information as the last time the user received a facsimile on the computer, etc., to decide whether or not to allow access. Specifically, an ASR/semantic analyzer and/or a speaker recognition module, such as those discussed above, may be implemented in the user's computer to perform the verification process discussed herein. One of ordinary skill in the art will appreciate further variations to the above-described embodiments given the inventive teachings disclosed herein.
Referring now to FIG. 3, another embodiment of the invention, illustrated via a flow chart/block diagram, is shown. Such an embodiment provides a security system for processing a large number of users who are attempting to access a service/facility simultaneously or for processing a large user database. Specifically, the embodiment described below provides identification in a verification process with respect to a speaker via an iterative procedure that reduces a set of candidate speakers at each step via random questioning and voice identification on such set of candidate speakers until one candidate or no candidates are left.
Again, a potential user 12 calls a central server 22 via link 24 , identifies himself and requests access to the particular service/facility. Next, the server 22 provides the name of the user to a speaker-independent ASR 60 via link 62 . In response, the ASR 60 decodes the caller's name and provides a list of candidate names that match the caller's acoustic utterance to the server 22 via link 64 . However, as mentioned above, even if the speaker doesn't provide his/her name, the system may use other information and voice characteristics to generate the list of candidates.
Next, personal databases (block 66 ) of users with names from the list are activated. These databases are activated through the larger set of databases 18 of all the service/facility users via links 63 and 65 . The selected databases contain personal user data, such as age, profession, family status, etc., as well as information about the user's voice, such as prototypes, prosody, speech rate, accent, etc. The types of information in the databases will be described later in greater detail.
Still further, a voice classification module 68 is accessed via link 69 . The module 68 , which performs a voice classification analysis, checks for certain voice characteristics of the caller and browses the selected databases 66 via link 67 to eliminate users who do not fit these characteristics, thus narrowing the list of possible candidates. Next, a random question relevant to the user databases that remain as candidates after the voice classification analysis is presented to the user via link 70 . The user provides his answer to the question via link 72 and the server 22 , via the ASR 60 , uses the answer to eliminate more of the candidates. Further, the server 22 uses the user's voice sample from the answer to run a more precise voice classification analysis via module 68 to reduce the list of candidates even further. This procedure continues iteratively with more random questions and with more detailed levels of speaker classification analysis until one or none of the candidates remain. As mentioned, the use of random questions in an iterative process makes the fraudulent use of recorders or synthesizers to fool the system substantially useless. Also, the use of a relatively large quantity of random questions overcomes the known problem of speech recognition and natural language understanding techniques making recognition and understanding errors.
A variation to the above embodiment includes the scenario wherein the user 12 provides a password to the server 22 which he shares with a group of other users. In this way, the server 22 initially narrows the possible candidate databases from the set of databases 18 before asking any questions or accessing the voice classification module 68 . Once the list of user databases are limited by the password, then the above iterative process may be performed to identify one of the candidates or to exclude all candidates.
As mentioned previously, while multiple links between modules are illustrated in the figures, they are meant to illustrate functional interaction between modules rather than actual physical interconnection, although a physical implementation similar thereto may be employed. Also, one of ordinary skill in the art will appreciate further variations to the above-described embodiments given the inventive teachings disclosed herein.
Referring now to FIG. 4, a block diagram illustrating the possible types of information contained in a user database 18 is shown. The use of such non-acoustic information, as previously explained, significantly improves the performance of the security measures described with respect to the invention. In addition, a variety of acoustic information may be included in the databases.
The information may be categorized as information exhibiting static features, i.e. information that does not change or changes slowly or periodically with time (block 102 ), and information exhibiting dynamic features, i.e., information that changes quickly or non-periodically with time (block 104 ). In other words, static information is a function of the caller/user and dynamic information is a function of the request. Static information may be either internal (block 106 ) or external (block 108 ). Examples of external information are phone numbers, time of day, etc. Internal information may be further categorized as information extracted from the dialog between the user and the server, such as gender, speech rate, accent, etc., or information decoded from the dialog by the ASR, such as name, address, date of birth, family status, etc. On the other hand, dynamic information may include information regarding the caller's trips, meetings with people, facsimile and e-mail information. For instance, if the system of the invention is implemented on the user's computer, as previously mentioned, then the system may query the user who is seeking remote access thereto by asking whether the user received e-mail from a particular person on a particular day. It is to be appreciated that the present invention can dynamically create new questions (from information provided in real-time), understand the respective answers and then use the information during the next transaction. Automatic enrollment of a new user may also be accomplished in a similar manner.
Referring now to FIG. 5, a flow chart/block diagram illustrating the generation of user model 20 , formed according to the invention, is shown. As previously explained, a user model is employed to estimate a probability of a particular user's identity. The model is utilized in accordance with the text-independent speaker recognition module 52 (FIG. 2) and the voice classification module 68 (FIG. 3 ). It is to be appreciated that the static and dynamic information utilized in the models is usually distinct from any other information provided and utilized in response to the random questions, but this is not a necessary condition.
The user information that was described with respect to FIG. 4 may be advantageously used to generate a model of users in order to enhance the text-independent speaker recognition process performed by module- 52 (FIG. 2) and the voice classification process performed by module 68 (FIG. 3 ). It is to be understood that such a model does not produce a user's acoustic score but rather estimates a probability of a given user's identity from a known user's database. In one particular form, one can interpret a search of a best matching speaker with respect to acoustic data as a maximum value of a function defined as the conditional probability of a speaker (speaker.) given the acoustic data utilized from the speaker dialog, i.e., P(speaker i |acoustic data). It is generally known in speech recognition that such a conditional probability may be computed by converting such equation to P(acoustic data|speaker.) P(speaker i ). This general speech recognition equation is designated as block 202 in FIG. 5 . It is further to be understood that P(acoustic data speaker i ) may be computed using some acoustic models for speakers that may be represented as Hidden Markov Models (HMM). In,. another embodiment, one can interpret P(speaker i ) as a weighted factor and update a general speaker score using a known formula.
As long as there is a satisfactory U-measure (block 204 ) on a user database, one can apply the strategy used in speech recognition to reduce the size of short lists of speakers and exclude speakers from the acoustic recognition process as long as their U-measure is below some predetermined threshold value. U-measure calculation is a statistical measure on a set of users. The term “U-measure” simply refers to a user measure or a measure on a user population. The measure may be any standard statistical measure on some set of events. In the context of the invention, the events are that some users from a set of users will try to access a service and/or facility. The measure on the set is used to derive a probability that some event or set of events may occur. A standard reference of probabilistic measure on some set may be found in the reference: Encyclopedia of Mathematics, Vol. 6, Kluwer Academic Publishers, edited by M. Hazewinkel, London (1990).
In order to estimate the U-measure for all users in the database, one can use one of the following procedures. First, one may introduce some static parameters (features) that characterize system users, i.e. profession, sex, hobby, etc., and denote them as S 1 , S 2 , S 3 , . . . S j . Likewise, dynamic parameters (features) may be introduced, i.e. age, time when a person attempts to access the service/facility, location from which the caller is calling, etc. and denote them as D 1 , D 2 , D 3 , . . . D k . Now, one can estimate P(S j |D k ) from training samples (block 208 b ) for some users within the overall user database ( 208 ). The estimation of the static parameters S j and dynamic parameters D k are respectively done in blocks 210 and 212 . Then, for any new user (block 208 a ), one can estimate his U-score, such as thy product of all P(S j |D k ) where S j are taken from the new user's database.
Additional special parameters can be introduced in the set S j . Such parameters may be vocabulary, prosody, speech rate, accent, etc. Essentially, this data can be obtained from the acoustic front-end of the automatic speech recognizer prior to speech recognition.
Other measures which represent the probability of a speaker given a parameter, including more complex models, may be employed and, as a result, the invention is not limited to the use of a U-measure of the static and dynamic parameters described herein.
In addition, the speaker identity claim can be done automatically via a speech and speaker recognition process. At the beginning of the conversation between the user and the central server, the speaker will provide his name and some information such as his address or the object of his request. An acoustic front-end in the speech recognizer (such as ASR 28 in FIG. 2) extracts the acoustic features associated with these first spoken utterances. The utterances are recognized and processed by a natural language understanding module within the speech recognizer in order to identify the name of the user and the address, if available. The stream; of acoustic features are also fed to a text-independent speaker recognition module (such as module 52 in FIG. 2) which provides the system with a list of potential users. By searching for matches between the recognized name and the top-ranked identified speakers, the identity claim is obtained. Alternatively, the recognition of the name reduces the population of candidates to a subset, namely, the set of speakers with the same name. Then, the speaker identification process establishes the correct identity claim. Similarly, the requested service may be automatically recognized'and different levels of security or tolerance may be established based on the type of request. Also, both approaches may be combined. The system may recognize the name and address of the speaker; however, recognition and/or understanding errors may occur and/or a list of speakers with the same name/address may exist. Thus, by using speaker recognition (preferably, text-independent) on the same data, the list of candidates may be reduced to a small number or to one particular user. If a substantial set of candidates still exist, random questions may be used to decide who the speaker is before going through the verification process.
The advantage of having a text-independent speaker recognition engine is apparent when the actual service is provided. The stream of acoustic features fed to the speech recognition engine and its natural language understanding module may also be fed to the text-independent speaker recognition module which runs in the background and verifies that over the whole interaction, using a large amount of test data, that the speaker verification still matches. Advantageously, problems can be flagged and depending on the service, the service may be interrupted or an operator may be called or a subsequent verification may be requested whereby the transaction is temporarily put on hold until the re-verification is accomplished.
The following is one example of an implementation of the speaker verification principles described herein. However, it is to be appreciated that the present invention is not limited to this particular example and that one of ordinary skill in the art will contemplate many other implementations given the teachings described herein.
The feature vectors (obtained as an output of the acoustic front-end of the speech recognizer) are of the mel cepstral, delta and delta-delta type (including C0 energy). These feature vectors are 39 dimension vectors and are computed on frames of about 25 milliseconds with shifts of about 10 milliseconds. It is to be appreciated that the speaker recognition module and the speech recognizer may use the same types of feature vectors; however, this is not critical to the invention. The speaker identifier is a vector quantizer which stores, during enrollment, a minimum of information about each speaker. All the input feature vectors are clustered in a set of about 65 codewords. Typically, about 10 seconds of speech are required for enrollment. This is easily obtained as the new user enrolls all of his aliases. However, when the user interacts with the system rather than for the purpose of enrolling his aliases, data obtained may be used to build acoustic models of the voice prints. In practice, all the data from the user enrollment is used. Note that when a new speaker is enrolled, it does not affect any of the previous models.
When an enrolled speaker uses the system, the acoustic features are computed and simultaneously given to the speaker identification system and to the speech recognizer. The speaker identification/verification/classification phase is implemented as a vector quantizer decoder. On a frame by frame basis, it identifies the closest codebook (or ranks the N closest codebooks). An histogram is created which counts how many frames have been selected for each codebook. The codebook which is most often selected identifies the potential speaker. By looking at the average distance from the closest codebook, it is possible to detect new users. In this case, the new user is then prompted with an enrollment menu in order to perform the enrollment process.
Different embodiments may be employed for the text-independent speaker verifier. Again, the feature vectors (obtained as the output of the acoustic front-end) are of the mel cepstral, delta, and delta-delta type (including C0 energy). They are preferably 39 dimension vectors and are computed at the user end or at the server end. The features are usually computed on frames of about 25 milliseconds with shifts of about 10 milliseconds. The speaker verifier is preferably a vector quantizer which stores, during enrollment, a minimum of information about each speaker. All the input feature vectors are clustered in a set of about 65 codewords (centroids and variances). Typically, about 10 seconds of speech are required for enrollment. The speaker verification phase is implemented as a vector quantizer decoder. On a frame by frame basis, the closest codebook is identified or the N closest codebooks are ranked. An histogram is created which counts how many frames have selected each codebook. The codebook which is most selected identifies the potential speaker. Acceptance or rejection of test speakers is based on the average distance from the codebooks of the testing vectors versus the average variance of the codebook provided that the identified speaker matches the identity claim and by comparing the scores to the scores obtained from “cohorts” of the speaker as described in U.S. Ser. No. 081788,471. Cohorts are sets of similarly sounding speakers who are in the database. The verification results from a competition between the speaker model and the models of the cohorts or background (new model built over the whole cohort group) models. The identity claim is tried over all the users who have access to the function protected by the system. The speaker classification is performed by doing identification with models obtained by clustering close codebooks associated with similar speakers.
It is to be appreciated that, in order to implement the embodiments described herein, various existing components may be implemented. For instance, a speech recognizer (such as shown as ASR 28 in FIG. 2 and speaker-independent ASR 60 in FIG. 3) may be implemented using a classical large vocabulary speech recognition engine using Hidden Markov Models, mixtures of Gaussian probabilities, mel cepstral vectors as acoustic features, a 20K or 64K vocabulary and a trigram language model. Such systems, for example, are disclosed in IBM's speech dictation engine “Simply Speaking” and in “Transcription of Radio Broadcast News with the IBM Large Vocabulary Speech Recognition System”, P. S. Goplalakrishnran et al., Proceeding Speech Recognition Workshop, Arden House, Drapa (1996). Further, while it is preferred that. a text-independent speaker recognition module (module 52 of FIG. 2) is utilized, text-dependent or text-prompted speaker recognition modules may also be used. Such systems are described in the Furui article (text-dependent speaker recognition) and in U.S. Ser. No. 08/788,471 (text-independent speaker recognition). Preferably, a natural language understanding module which relies on a combination of classical parsing capabilities with key word spotting and speech recognition may be employed, such as disclosed in the article “Statistical Natural Language Understanding Using Hidden Clumpings”, M. Epstein et al., ICASSP Proceedings, pg. 176, Vol. 1, (1996). However, other methods of implementing natural language understanding may be employed.
Furthermore, a voice classification module such as is disclosed in either U.S. Ser. No. 08/787,031 or the patent application entitled, “Speaker Recognition Over Large Population with Combined Fast and Detailed Matches”, filed on May 6, 1997, may be employed to perform the functions of the voice classification module 68 . A score estimator such as is disclosed in U.S. Pat. No. 5,502,774 (Bellegarda et al.) may be employed to perform the functions of the score estimator 44 . A semantic analyzer as is disclosed in either of the articles: G. Gazdar and C. Mellish, Natural Language Processing in PROLOG—An Introduction to Computational Linguistics (1989); P. Jacobs and L. Rau, Innovation in Text Interpretation, Artificial Intelligence, Vol. 63, pg. 143-191 (1993); W. Zadrozny et al., “Natural Language Understanding with a Grammar of Constructions”, Proceedings of the International Conference on Computational Linguistics (August 1994).
Although the illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be affected therein by one skilled in the art without departing from the scope and spirit of the invention. | A method of controlling access of a speaker to one of a service and a facility, the method comprising the steps of: (a) receiving first spoken utterances of the speaker, the first spoken utterances containing indicia of the speaker;(b) decoding the first spoken utterances; (c) accessing a database corresponding to the decoded first spoken utterances, the database containing information attributable to a speaker candidate having indicia substantially similar to the speaker; (d) querying the speaker with at least one question based on the information contained in the accessed database; (e) receiving second spoken utterances of the speaker, the second spoken utterances being representative of at least one answer to the at least one question; (f) decoding the second spoken utterances; (g) verifying the accuracy of the decoded answer against the information contained in the accessed database serving as the basis for the question; (h) taking a voice sample from the utterances of the speaker and processing the voice sample against an acoustic model attributable to the speaker candidate; (i) generating a score corresponding to the accuracy of the decoded answer and the closeness of the match between the voice sample and the model; and (j) comparing the score to a predetermined threshold value and if the score is one of substantially equivalent to and above the threshold value, then permitting speaker access to one of the service and the facility. | 6 |
FIELD OF THE INVENTION
[0001] The present invention is related to methods for coating a substrate with a coating comprising conjugated polymers, i.e. polymers with a molecular structure adapted to conduct electricity after the addition of a proper doping element.
STATE OF THE ART
[0002] In general, organic polymers are known to be electrical isolators. However, this view changed by the revolutionary discovery of conductivity in I 2 -doped polyacetylene in 1977 by the groups of Alan J. Heeger, Alan G. MacDiamid and Hideki Shirakawa.
[0003] Polyacetylene belongs to a special group of organic polymers, conjugated polymers, which have the ability to conduct electricity upon doping. Doping is a chemical process (oxidation or reduction) which creates charges on the polymer chain. Conjugated polymers have alternating single and double bonds, which allow them to transport these charges along the chain and hence conduct electricity.
[0004] Among the best known conjugated polymers are polyaniline (PANI), polypyrrole (PPy), polythiophene (PT), polyphenylenevinylene (PPV) and derivatives thereof. Conjugated polymers have some important advantages over classic semiconductors (e.g. silicon semiconductors) which make them very interesting from an economic point of view: they are light weight, flexible and can be used for large-area applications.
[0005] Besides the ability to conduct electricity, conjugated polymers have also other unique properties which make them suitable for various applications. They are used today in polymer light emitting diodes (polyLEDs), as antistatic coatings and for corrosion protection of metals. Also some more complex plastic electronic applications are being developed such as organic solar cells, polymeric transistors and organic (bio)sensors.
[0006] The chemical structure of conjugated polymers, consisting of alternating single and double bonds, results in rigid polymers which have a very low solubility. Upon doping, the solubility of most polymers is even more reduced. Conjugated polymer coatings are generally formed by chemical or electrochemical techniques. However, some vacuum plasma coating depositions have also been reported. Examples of plasma coating under vacuum of conjugated polymers can be found for example in WO2005/092521, U.S. Pat. No. 6,207,239, US2003/0235648, US2004/0090460, U.S. Pat. No. 6,228,436 and U.S. Pat. No. 6,274,204.
[0007] In electrochemical polymerization, a monomer is dissolved into an electrolyte solution of an electrochemical cell. By applying a potential difference between the electrodes, polymerization starts and the conjugated polymer is deposited onto one of the electrodes. In practice, the substrate to be coated is generally used as electrode. For example, the electrodeposition of polypyrrole on a mild steel electrode for corrosion protection, as described by Krstajic, N. V., B. N. Grgur, S. M. Jovanovic and M. V. Vojnovic, Corrosion protection of mild steel by polypyrrole coatings in acid sulfate solutions . Electrochimica Acta, 1997. 42(11): p. 1685-1691. Today, electropolymerization of conjugated polymers is well documented in literature.
[0008] During conventional polymerization (radical polymerization, polycondensation, . . . ) of conjugated polymers in solution, precipitation often occurs due to the low solubility of the polymers. This creates difficulties for subsequent purification steps and the coating procedures (spin coating, drop casting, . . . ) on substrates for final application. In order to avoid these drawbacks, monomers with flexible side chains are used to make the resulting conjugated polymers more soluble in (polar or apolar) solvents.
[0009] A rather new strategy for forming conjugated polymer coatings is the use of a plasma deposition process. For example, in document EP-A-1144131 or U.S. Pat. No. 6,207,239, a monomer vapor or aerosol is brought into a vacuum chamber and passed through a glow discharge electrode, creating a monomer plasma. In the vacuum plasma, the monomer is polymerized and deposited onto a substrate, forming a conjugated polymer coating. Polymerization in a vacuum plasma is, however, a rather expensive batch technique. Atmospheric plasma polymerizations can be done in a continuous manner with much cheaper equipment. For example, patent EP-A-1326718 describes a method to deposit polymer coatings on a substrate by injecting an aerosol into an atmospheric pressure glow discharge. The document also discloses examples of the deposition of conjugated polymer coatings with this technique. The necessity for a glow discharge and the large inter-electrode gap are still some limitations in the invention of EP-A-1326718. It's difficult to sustain a uniform glow discharge in gasses as nitrogen or air, especially when reactive chemicals are injected in the plasma discharge. For this reason, the carrier gas is restricted to noble gasses as for example Helium.
[0010] So far in the prior art, the doping of a conjugated polymer coating takes place after the actual coating step. The drawback of this technique is that it is difficult in this way to obtain a homogeneous distribution of the dopant throughout the coating's thickness. Often, the dopant concentration will be higher near the surface of the coating, than near the coating's contact plane with the substrate. This also has a negative effect on the stability of the dopants, which are more likely to move out of the coating by diffusion.
AIMS OF THE INVENTION
[0011] The present invention aims to provide a method which does not suffer from the drawbacks of the prior art.
SUMMARY OF THE INVENTION
[0012] The invention is related to a method as described in the appended claims. It concerns a method for the deposition of conjugated polymer coatings via atmospheric or intermediate pressure plasma polymerization, with the simultaneous introduction of a second material into the plasma discharge. The second material can be a doping agent. It can be any other chemical agent, added for example for the purpose of obtaining organic/inorganic hybrid coatings. The coating of the invention can be obtained from one specific monomer or a copolymerization of two or more monomers of conjugated polymers. Organic/inorganic hybrid coatings deposited according to the invention, contain conjugated building blocks from a mixture of monomers and said other chemical agents. As such, conjugated polymer coatings can be obtained with improved adhesion to the substrate and better mechanical properties through a higher degree of crosslinking with the coating and with the substrate surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates an installation suitable for performing the method of the invention.
[0014] FIG. 2 represents the structure of a number of conjugate polymers.
[0015] FIG. 3 illustrates a continuous process to form multilayers according to the method of the invention.
[0016] FIG. 4 shows the UV-VIS spectrum of the coating of example 2.
[0017] FIG. 5 shows the UV-VIS spectrum of the in situ doped plasma polypyrrole coating in example 3, described further.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The invention is concerned with a method for forming a conjugated polymer coating on a substrate by plasma deposition. This method is characterized by the introduction of an additional material into the plasma discharge at atmospheric or intermediate (1 mbar to 1 bar) pressure. According to the method, a substrate is placed in or led through a plasma discharge or placed or led through the gas stream coming from a plasma discharge. Injecting a conjugated polymer precursor (monomer) or a plurality of different precursors in the plasma or the gas stream coming from the plasma discharge results in the deposition of a conjugated polymer coating onto the substrate. Simultaneously (i.e. ‘in situ’), the additional material is introduced into the discharge. The second material can be a doping agent (oxidizing, reducing or acid/base agent), injected into the plasma discharge. The additional material is introduced during the plasma deposition, but not necessarily during the whole duration of said deposition. It may be added during one or more timespans, all taking place during the duration of the plasma deposition. The mixing of the conjugated polymer precursor and the additional material may take place before or during the introduction of the materials into the plasma. According to the preferred embodiment, the additional material is introduced through another supply means than the supply means used for introducing the coating forming material. This means that the coating forming material is not mixed with the additional material, before the introduction of the mixture into the plasma discharge. The additional material is thus introduced into the discharge through a channel which is separate from the coating forming material supply, e.g. through a separate aerosol generator. According to another embodiment, two aerosol generators are in place but the atomized materials are mixed before the mixture is introduced into the plasma.
[0019] An example of an atmospheric pressure plasma reactor is the dielectric barrier discharge, depicted in FIG. 1 . The apparatus ( 4 ) comprises a pump ( 7 ) to evacuate the gases, possibly with a control valve ( 8 ). An inlet port with possibly a control valve for the gases ( 5 ) coming from a gas supply unit ( 6 ) and the aerosols ( 13 ) coming from an aerosol generator ( 9 ). It also comprises at least one set of electrodes ( 1 and 2 ). The power supply ( 3 ) is connected to at least one of the electrodes. The other electrode can be grounded, connected to the power supply ( 3 ), connected to a second power supply or connected to the same power supply with an (90°) out of phase potential. Voltage, charge and current measurements can be performed by means of an oscilloscope ( 10 ). For this, one can use respectively a voltage probe ( 12 ), a capacitor ( 11 ) and a current probe. Conditions to create a plasma are a frequency between 50 Hz and 10 MHz, a power range between 0.05 W/cm 2 and 100 W/cm 2 , and an electrode gap between 0.01 mm and 100 mm.
[0020] Besides the dielectric barrier discharge, other techniques for generating an atmospheric pressure plasma may be used, such as for example a RF or microwave glow discharge, a pulsed discharge or a plasma jet. Depending on the application, further adjustments concerning for example mechanical strength, conduction or deposition rate can be achieved by applying an intermediate pressure (0.1 to 1 bar) instead of an atmospheric pressure.
[0021] Depending on the application, a different method for injection of the coating forming precursor may be necessary. High precursor concentrations can be injected into the plasma with an aerosol generator. An aerosol can be generated with liquids, solutions or sol-gel. Examples of aerosol generators are ultrasonic nebulizers, bubblers or electrospraying techniques. Electrostatic spraying techniques allow to charge or decharge the precursor before entering the plasma. The precursor can also be injected as a gas or a vapor.
[0022] A typical precursor for forming a conjugated polymer coating can be an organic monomer, such as an aromatic heterocycle or substituted benzene. Examples of aromatic heterocyclic precursors include, but are not limited to thiophene, pyrrole and furan. Also derivatives of former heterocycles are interesting precursors. Examples include, but are not limited to 3,4-ethylenedioxythiophene, isothionaphtene, 2,5-dibromothiophene, 2,5-diidothiophene, 2-bromo-5-chlorothiophene, 3-bromo-2-chlorothiophene, 2-bromo-3-methylthiophene, 3-bromo-4-methylthiophene, 2-bromothiophene, 3-bromothiophene, 3-butylthiophene, 2-chlorothiophene, 3-chlorothiophene, 3-methylthiophene, tetrabromothiophene, 2-iodothiophene, thiophene-3-carbaldehyde, 3-acetylthiophene, 2-(3-thienyl)ethanol, thiophene-3-carboxylic acid, 2,3-dibromothiophene, 2,4-dibromothiophene, 3,4-dibromothiophene, 2-chloro-3-methylthiophene, 3-thiophenecarbonyl chloride, 3-thienylmethanol, N-methylpyrrole, 1-(2-aminophenyl)-pyrrole, pyrrole-3-carboxylic acid, 3-(1H-pyrrol-1-yl)aniline, and 4-(1H-pyrrol-1-yl)aniline.
[0023] Another type of precursor that can lead to conjugated polymers are substituted benzenes such as for example aniline or α,α-dichloro-p-xylene. Also derivatives of former substituted benzenes may be interesting. Other derivatives of above mentioned precursors are those that have tails substituted on their main structure. Examples of such tails are branched alkyl tails, functionalized alkyl tails, polyethyleneoxide tails. These tails can be used to enhance solubility of the polymers in certain solvents. Also attachment of certain functional groups or enzymes can be made possible which can be useful in for example organic sensors. An example of such functional group for a sensor is a PH active group such as ammonia or acid groups. The substituted tails can also be used to enhance crosslinking. The list above gives a good overview of the available precursors, but the invention is not limited to these precursors.
[0024] Conjugated polymers can also be formed from polycyclic aromatic compounds. Examples of polycyclic aromatic compounds include, but are not limited to naphthalene, anthracene, triphenylene, chrysene, coronene, pentacene benzanthracene, perylene, benzoperylene, phenanthrene, pyrene, benzopyrene, rubicene and derivatives thereof.
[0025] Most conjugated polymer forming precursors belong to the categories described above. However, there are some exceptions. An example of such an exception is acetylene.
[0026] In stead of organic monomers, also oligomers or low molecular weight polymers may be injected into the plasma. These oligomers and polymers are chemically or electrochemically synthesized with one of the above mentioned monomers. Also chemically or electrochemically synthesized copolymers from two or more of the before mentioned monomers may be injected.
[0027] Together with a first coating forming material, an additional conjugated polymer forming precursor can be added in order to become a conjugated copolymer coating. Such conjugated copolymers can have, for example, a better conductivity than the two homopolymers. Copolymerization with an organic precursor that does not form conductive polymers may be useful to improve for example crosslinking densities and barrier properties or to introduce certain specific properties such as for example PH buffering. Examples of interesting precursors for copolymerization are (meth)acrylates, which enhance crosslinking. Examples of such acrylates include, but are not limited to methyl methacrylate, methyl acrylate, ethyl acrylate, 2-hydroxyethyl methacrylate, trans-methyl crotonate, trans-ethyl crotonate, butyl acrylate, allyl methacrylate, vinyl crotonate, butyl methacrylate, ethyl-3-ethoxy acrylate, ethylene diacrylate, methylcinnamate, cyclohexyl methacrylate, 4-hydroxybutyl acrylate, hexyl acrylate, methyl-3-methoxy acrylate, 2-hydroxyethyl acrylate, ethylene glycol methyl ether acrylate, lauryl methacrylate, ethyl crotonate, 2-hydroxypropyl methacrylate, isobutyl methacrylate and tert-butyl acrylate.
[0028] According to the invention, an additional material is added—in situ—to the plasma, together with the addition of the conjugated polymer coating forming pre-cursor (in the case of a polymer coating) or together with the addition of the plurality of precursors (in the case of a co-polymer coating).
[0029] According to a first embodiment of the invention, the additional material is an inorganic or mixed organic/inorganic pre-cursor which forms an organic-inorganic hybrid coating by chemical or physical bonding with the organic conjugated polymer precursor(s). Examples of such an inorganic material are organo silicium precursors. The organo silicium precursor can copolymerize with the conjugated polymer precursor. The so formed copolymer may have a higher crosslinking density which improves mechanical properties of the conjugated plasma coating. The inorganic part of the plasma polymerized hybrid conjugated polymer coating may also react with certain substrates, which improves adhesion to these substrates. Since the plasma polymerization occurs in a continuous gas flow, the concentration of both the conjugated polymer precursor and the hybrid precursor in the plasma stays constant. This results in hybrid conjugated polymer coatings with a homogeneous composition. Examples of organosilicium precursors include but are not limited to hexamethyldisiloxane, diethoxydiethylsilane, glycidoxypropyl trimethoxysilaan, tetraethoxysilane, triethoxyvinylsilane, hexamethyltrisiloxane, hexamethyldisilane, hexamethyldisilazane, methyltriethoxysilane, methyltrimethoxysilane, tetraethylorthosilcate, 3-mercaptopropyltriethoxysilane, vinyltris(2-methoxyethoxy)-silane, allyltriethoxysilane, (3-glycidoxypropyl)-trimethoxysilane. Also metallocenes can be used to form hybrid coatings. Acrylates, organosilicium compounds and metallocenes are the most common used precusors for hybridisation, but the invention is not limited to these types of precursors.
[0030] According to a second embodiment the second material is a reagent that adjusts the conductivity to that which is necessary for a certain application. These reagents are called dopants or dedopants. According to the invention, the doping (or dedoping) and polymerization occurs simultaneausly, so that the dopant is built in into the entire bulk of the plasma coating. In situ doping (i.e. simultaneous with the plasma deposition) does not have the disadvantages described above. This bulk doping method results in a stable doping with high conductivities.
[0031] As stated, in situ doping can be done by injecting the dopant simultaneously with the coating forming precursor into the plasma. This is done with one of the injection methods described above for the injection of the coating forming precursor. A liquid or dissolved dopant may thus be added as an aerosol, but the dopant can also be injected as a gas or vapour.
[0032] There are two types of doping agents, acceptors and donors. Examples of the acceptor type dopant are halogens such as Cl 2 , Br 2 , I 2 , ICl, ICl 3 , IBr and IF; Lewis acids such as PF 5 , AsF 5 , SbF 5 , BF 3 , BCl 3 , BBr 3 and SO 3 ; protonic acids such as HF, HCl, HNO 3 , H 2 SO 4 , HClO 4 , FSO 3 H, ClSO 3 H and CF 3 SO 3 H; organic acids such as acetic acid, formic acid and amino acid, transition metal compounds such as FeCl 3 , FeOCl, TiCl 4 , ZrCl 4 , HfCl 4 , NbF 5 , NbCl 5 , TaCl 5 , MoCl 5 , WF 5 , WCl 5 , UF 6 , LnCl 3 and anions such as Cl − , Br − , I − , Clo 4− , PF 6− , AsF 5− , SbF 6− , BF 4− and sulfonate anions. Examples of donor dopants are alkaline metals such as Li, Na, K, Rb and Cs; alkaline earth metals such as Ca, Sr and Ba; rare earth metals such as Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er and Yb; an ammonium ion; R 4 P + , R 4 As + and R 3 S + and acetylcholine. Examples of dedoping agents are reducing agents, such as hydrazine or ammonia.
[0033] In-situ doping according to the invention has a number of advantages. Doping of the conjugated plasma coating after polymerization is less efficient because the doping material has to penetrate the coating. Usually only a part of the coating is doped. When in situ doping is used, larger doping agents can be incorporated into the plasma polymer coating. This not only dopes the entire bulk of the film but also makes diffusion of the doping agent out of the film more difficult. This gives stable doped conjugated plasma polymer coatings with better conductivity.
[0034] The properties of the conjugated polymer coatings can be further optimized by multi-step plasma processes. For example, an application may exist of a pre-treatment of the substrate with a nitrogen plasma, which improves adhesion with the substrate. In a second step an (in situ doped) conjugated polymer coating may be plasma deposited. In a third finishing step, a barrier coating may be deposited onto the conjugated layer to protect this conjugated plasma polymer layer from environmental influences. Such multi-layer coatings can be formed in one and the same reactor by changing the injected gas mixture and aerosol after a certain period of time. However, from an industrial point of view, it is more interesting to place different atmopheric pressure plasma discharge reactors in a line, to form the multi-layers in a continuous manner. The substrate can be moved by, for example a roll-to-roll system from one reactor to the next where consecutive deposition or activation reactions are performed (FIG. 3 ).]
EXAMPLES
Example 1
[0035] For this experiment, a dielectric barrier reactor with one diëlectricum was used. The lower electrode is covered with a glass diëlectricum and a high ac voltage is created on it. The upper electrode consisted of a grounded metal plate. The gap between the upper electrode and the glass was 1.5 mm. A thin glass plate was used as a substrate. After cleaning the substrate with isopropanol, it was placed on the glass diëlectricum.
[0036] The conjugated polymer forming precursor is thiophene. It is brought into the plasma reactor by atomizing the thiophene liquid with 2 bar of nitrogen gas. This atomized thiophene is then transported with 20 l/min of nitrogen carrier gas. The plasma was created with a power of 0.13 W/cm 2 and a frequency of 1.5 kHz. The reaction lasted for 3 minutes.
[0037] The plasma reaction leads to a yellow-brown deposition. This coating has a thickness of around 250 nm. Infrared spectroscopy shows a large band around 1400 cm −1 and a couple of small bands around 1550 cm −1 which are typical for a heterocyclic aromatic five ring. This means that at least a part of the conjugated structure is still intact after plasma polymerization. Doping with iodine results in a conductivity of 2×10 −3 S/cm at a temperature of 20° C. and a relative humidity of 50%.
Example 2
[0038] The same reactor setup as in example 1 is used. The conjugated polymer forming precursor is the thiophene derivative 3,4-ethylenedioxythiophene (EDOT). It is brought into the plasma reactor by atomizing the EDOT liquid with 2 bar of nitrogen gas. This atomized EDOT is then transported with 10 l/min of nitrogen carrier gas that is mixed with 1% oxygen. The frequency used, was 1.5 kHz and the inter electrode gap is 1.5 mm. The plasma was created with a pulsed power of 0.27 W/cm 2 . This means that the power input was not continuous. Power was switched on and of f during polymerization. The ‘on time’ lasted for 5 s each cycle. The ‘off time’, in which there is precursor flow without plasma, also lasted for 5 s each cycle. In this pulsed status, the reaction conditions are less severe and monomer breakdown decreases. The total reaction time was 5 minutes.
[0039] The oxidative environment in the plasma reactor results in an in situ doping of the plasma polymerized polyEDOT coating. A conductivity of 1×10 −3 S/cm was measured at 20° C. and a relative humidity of 50%. The PEDOT coating has a blue color because of it's absorption in the visible range of the light spectrum. As can be seen in the UV/VIS absorption spectrum (UV/VIS spectroscopy is a technique that measures the light absorption of a material at wavelengths in the visual and the UV-area) ( FIG. 4 ), the plasma polyEDOT has a broad absorption peak around 700 nm, which is typical for the conjugated system of these kind of materials.
Example 3
[0040] In situ doping of plasma polymerized conjugated polymer coatings can be accomplished with the same set-up as in example 1. A second injection channel is used to inject the dopant. The precursor in this example is pyrrole. Iodine vapor is used as a doping agent. It is injected by vaporizing solid iodine, by heating. The iodine vapour is then pumped directly into the plasma.
[0041] The conjugated polymer forming precursor, pyrrole, is injected by using an atomizer with a nitrogen pressure of 2 bar. The atomized pyrrole is transported with 10 l/min of nitrogen carrier gas. The plasma was created with a power of 0.18 W/cm 2 and a frequency of 1.5 kHz. The reaction lasted for 3 minutes.
[0042] The FIG. 5 shows the UV-VIS spectrum of the in situ doped plasma polypyrrole coating. Three absorption bands are present. The peak at 290 nm is the absorption of the aromatic ring structure of pyrrole. The absorption band of the η−η* transition of conjugated polypyrrole can be found at 380 nm. At 680 nm the bipolaron absorption of doped polypyrrole can be seen. The presence of the absorption bands at 380 and 680 nm shows that the plasma polymerized polypyrrole has a conjugated system and that this conjugated system is partially doped. Table 1 shows the relative amount of iodine in the conjugated plasma; polymer coating at different depths, measured by XPS. The relative amount of iodine into the coating is 3 to 4 percent. Sputtering of the coating surface, followed by another XPS measurement allows to measure the atomic composition in the bulk of the coating. Measurement of the relative iodine amount after different sputtering times (i.e. at a different depth into the coating) proves that iodine is found in the entire bulk of the coating in equal amounts. In situ doping of plasma polymerized conjugated polymers thus results in a homogeneously doped coating.
[0000]
TABLE 1
Sputtering time
0 s
5 s
40 s
100 s
Relative iodine amount
3.9%
4.0%
3.1%
3.3%
Example 4
[0043] In order to form an organic/inorganic hybrid coating, in which the organic part is a conjugated polymer (polythiophene), the experiment of example 1 is repeated with co-injection of vinyltriethoxysilane. This second precursor is injected by using a second atomizer with a nitrogen pressure of 0.5 bar.
[0044] After a reaction time of 3 minutes a yellow-brown coating is deposited. The thickness of the coating is around 680 nm. IR spectra show that the aromatic thiophene ring is still present (ring stretch band around 1400 cm −1 and ring in plane deformation band around 590 cm −1 ). Also some vibrations, typical for vinyltriethoxysilane are found in the IR spectra (for example a Si—O stretching band around 1050 cm −1 ). Further evidence for the presence of both precursors in the final coating is provided by XPS measurements. Table 2 shows that the coating contains both the elements sulfur (2p-electron binding energy: 164 eV) which is only found in thiophene and silicon (2p electron binding energy: 103 eV), which is only found in vinyltriethoxysilane
[0000]
TABLE 2
Electron binding
Relative amount
energy (eV)
Element
(%)
532
O
(1s)
33
401
N
(1s)
7
285
C
(1s)
46
164
S
(2p)
12.5
103
Si
(2p)
1.5
Example 5
[0045] In order to form a copolymer coating out of a conjugated (thiophene) and a non-conjugated precursor, the experiment of example 1 is repeated with co-injection of methylmethacrylate. This second precursor is injected by using a second atomizer with a nitrogen pressure of 0.5 bar.
[0046] After a reaction time of 3 minutes a yellow-brown coating is deposited. The thickness of the coating is around 580 nm. IR spectra show that the aromatic thiophene ring is still present (ring stretch band around 1400 cm −1 and ring in plane deformation band around 590 cm −1 ). Also some vibrations, typical for methylmethacrylate are found in the IR spectra (for example C—H stretching bands around 2900 cm −1 ; carbonyl stretch around 1715 cm −1 ; C—O ester stretch around 1150 cm −1 ). Further evidence for the presence of both precursors in the final coating is provided by XPS measurements. Table 3 shows that the coating contains sulfur (2p-electron binding energy: 164 eV) which is only found in thiophene. The large oxygen amount (1s electron binding energy: 532 eV) is due to the copolymerization with methylmethacrylate.
[0000]
TABLE 3
Electron binding
Relative amount
energy (eV)
Element
(%)
532
O
(1s)
28.5
400
N
(1s)
7.5
285
C
(1s)
51.5
164
S
(2p)
12.5 | A method produces a coating including a conjugated polymer on a substrate. The method includes the steps of: —providing a substrate, —introducing a conjugated polymer coating forming material into an atmospheric pressure plasma discharge, or into the reactive gas stream resulting therefrom, —simultaneously with the introduction of a coating forming material, introducing an additional material into the plasma discharge or the reactive gas stream resulting therefrom, —exposing the substrate to the plasma discharge or the reactive gas stream resulting therefrom, thereby obtaining the coating. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of my prior application Ser. No. 694,788 filed Jan. 25, 1985 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an abrasion resistant fabric particularly useful in dock shelters. Dock Shelters are used around doorways and openings in walls of buildings to protect building structure from impact with a truck body, and to provide protection from the weather in the space between the truck body and the building during the loading and unloading of the contents of the truck.
Dock shelters are made in several different ways. One popular version includes a flexible head curtain or panel of a heavy fabric of the type used for truck tarpaulins. The head panel is supported along its top edges and positioned to extend across the upper portion of a doorway or opening for engagement with the top of a truck body positioned for loading or unloading. Side curtains extend downwardly from the top of the opening and inwardly toward each other from the sides of the opening or doorway to engage the sides of a truck body being loaded or unloaded.
The head panel and side panels are subjected to considerable stress and wear because of the engagement with the truck body and because the panels are exposed to the wind and weather causing repeated flexing and snapping and considerable wear and strain requiring frequent replacement of the panels.
Another type of dock shelter uses cloth covered pads or bumpers on the corners and edges of the loading dock positioned for engagement with a truck as its moves into position for loading or unloading. The pads or bumpers may be filled with foam padding or may be inflatable as shown in U.S. Pat. No. 4,293,969.
The abrasion resistant fabric of this invention is useful in such dock shelters and in dock shelters of the type disclosed and claimed in U.S. Pat. No. 4,381,631 entitled LOADING DOCK SHELTERS and issued May 3, 1984 upon application of Sylvan J. Frommelt. The invention is also useful in other environments where the properties of abrasion resistance and flexibility are important in the fabric.
SUMMARY OF THE INVENTION
The abrasion resistant fabric of the present invention comprises a base or core coated on one or both surfaces with polyvinylchloride. A second coating of an abrasion resistant polymer or epoxy is applied in a dot or line configuration to the surface of the polyvinylchloride. The base fabric may be formed from yarn comprising synthetic fibers such as polyaramide, polyester, polypropylene, nylon, or any desired combination thereof, or from other fibers possessing comparable strength and fastness. The base fabric may be formed from such yarn by weaving, by weft insertion, and by knitting. Knitting for the core fabric is preferably done by the COFAB process. COFAB is a registered trademark of Gulf States Paper Corporation, P.O. Box 3199, Tuscaloosa, Alabama 35404. The abrasion resistant polymer may be polyvinylchloride, urethane, neoprene, Hypalon or other desired abrasion resistant material. The dot or line configuration of the second coating increases the abrasion resistance of the fabric and retains or, in some instances, obtains the flexibility desired for use of the fabric as dock shelters, dock pads, rail shelters, truck tarpaulins, tents and the like.
It is known to coat woven core fabrics with such abrasion resistant material as neoprene and Hypalon. In some instances the thickness of the coating which is sufficient to afford the desired abrasion resistance renders the fabric substantially inflexible or at least less flexible than desired. It has been found that applying an abrasion resistant coating in a dot or line configuration on a polyvinylchloride coated core fabric obtains the desired abrasion resistance with a thinner coating and lighter fabric having the desired flexibility.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view, with parts broken away, of a loading dock shelter;
FIG. 1A is a view similar to FIG. 1 illustrating a second type of loading dock shelter;
FIG. 1B is a view similar to FIG. 1 illustrating a third type of dock shelter;
FIG. 2 is a perspective view of the abrasion resistant fabric with the abrasion resistant coating applied in a dot pattern;
FIG. 3 is a sectional view taken substantially along the Line 3--3 in FIG. 2; and
FIG. 4 is a view similar to FIG. 2 but showing the abrasion resistant coating applied in a line pattern.
DETAILED DESCRIPTION OF THE INVENTION
Referring more specifically to the drawings, the numeral 10 broadly indicates an abrasion resistant fabric. Such fabric is useful in any environment where it is desired that the fabric have a high abrasion resistance and reasonable flexibility. One such environment is illustrated in FIGS. 1, 1A and 1B wherein a dock shelter is broadly indicated at 11.
In FIGS. 1, 1A, and 1B the dock shelter 11 includes a roof R and side walls W of conventional construction. The dock shelters of FIGS. 1 and 1A include a top panel broadly indicated at 12 and comprising a plurality of individual strips of abrasion resistant fabric 10 depending from the roof R and arranged in overlapping relation to each other beneath the roof R and between the side walls W. In FIG. 1, side panels broadly indicated at 13 are defined by overlapping vertically arranged strips of abrasion resistant fabric 10. In FIG. 1A, side panels 14 are defined by elongated strips of abrasion resistant fabric 10.
The inner margins of the top panel 12 and the side panels 13 of the dock shelter 11 define an opening O which is slightly less than the cross-sectional dimension of a truck body to be positioned in the dock shelter 11 for loading and unloading. So positioned, the top panel 12 engages the top of the truck body and the side panels 13 engage the sides of the truck body. The panels 12 and 13 are subjected to considerable stress and wear from repeated movement against the sides of the truck bodies caused by the movement of the trucks and the movement of the panels by the winds.
A third form of dock shelter is illustrated in FIG. 1B. There, the opening O has a cross-sectional area comparable to that previously described to accommodate an end of a truck or trailer being loaded or unloaded. The marginal edges of the opening O in FIG. 1B are defined by shock absorbent pads or bumpers 15 at the sides of the opening O and a shock absorbent pad or bumper 16 across the top of the opening. The pads 15 and 16 may comprise a core formed of resilient foam or the like an a covering of fabric 10. Or, the pads 15 and 16 may be pneumatic as shown in U.S. Pat. No. 4,293,969 with an outer covering of fabric 10.
In the prior art, fabrics intended for use as dock shelter fabrics were canvas or truck tarpaulin grade fabrics heavily coated with an abrasion resistant polymer such as vinyl or neoporene. The resulting fabric was heavy (35 ounces per yard) and stiff, measuring at least forty (40) mils in thickness.
The abrasion resistant fabric 10 of this invention has been developed to provide abrasion resistance without the sacrifice of flexibility heretofore considered inherent in the processing of cloth to improve its abrasion resistance. The fabric 10 comprises a core 20 woven, or otherwise formed, from the class of synthetic fibers described in the SUMMARY OF THE INVENTION and bonded on at least one surface with a first or base coating 21 of a polymer such as polyvinylchloride, urethane, a urethane/vinyl blend, neoprene, Hypalon, ethylene propylene diene terpolymer, chlorinated polyethylene, thermopolastic polyester ether elastomer, acrylic, or the like. A coating 22 of the same or corresponding material is preferably applied to the other side of the base or core fabric 20.
The coatings 21 and 22 are continuous along their respective surfaces of the core 20 and the coating 21 on the surface 23 intended to be exposed to abrasion is preferably thinner than the coating 22 on the other surface. The thickness of the base coating 21 on the exposed surface 23 has an inverse effect on the flexibility and on the abrasion resistance of the fabric. A thin base coat results in a flexible fabric with minimal abrasion resistance, while a thick base coat reduces the flexibility and increases the resistance to abrasion.
The base coat 21 applied to the exposed surface 23 of core fabric 20 is significantly thinner than that applied to prior art dock shelter fabrics so as to provide a flexible fabric. Satisfactory results have been obtained with a base coat 21 providing a composite thickness of twenty-five (25) mils, compared with forty (40) mils in the prior art dock shelter fabric.
According to the present invention, the degree of abrasion resistance can be increased while retaining the inherent flexibility of a thin continuous base coat of a desired polymer by applying in a spaced dot or line pattern on the base coat a second coat of an abrasion resistant polymer such as polyvinylchloride, chlorinated polyethylene, urethane, epoxy, or desired polymer blends as indicated at 24 in FIGS. 2, 3 and 4. The spaced pattern of the second coat 24 presents an effective abrasion resistant surface without sacrificing the flexibility of the fabric, as had been necessary in the prior art.
As a specific example, dock shelter fabric according to the invention with a continuous base coat on both surfaces of the core fabric and a discontinuous abrasion resistant coat fused to one surface of the continuous base coat weighs twenty-six (26) ounces per yard and measures thirty (30) mils overall.
An example of the discontinuous abrasion resistant coat 24 is a vinyl plastisol made from the following formulation:
150 lbs. of dioctyl phthalate used as a plasticizer
170 lbs. of polyvinylchloride polymer used as a binder
5 lbs. of Barium cadium zinc stablizer used as a stablizer
9 lbs. of aliphathic naptha used as a solvent
5 lbs. of colloidal silica used for the control of viscosity
30 lbs. of a desired color pigment dispersion
This formulation, or any desired formulation, for the abrasion resistant second coat 24 is placed on the base coat 21 in a known manner, as by putting a quantity of the formulation for the abrasion resistant second coat 24 in a vat in which an engraved roll is partially submerged for rotation with part of its circumference within the vat and part of its circumference above the vat. The roll is engraved with a spaced pattern defined by dots or lines, as desired. The core fabric 20 with its previously applied base coat of polyvinylchloride 21 on at least one surface is trained between the engraved roll and a pressure roll and the rolls are rotated to present a spaced pattern of the abrasion resistant plastisol 24 to the base coat 21 which is intended to become the exposed surface 23 of the fabric. A doctor blade may be used to present a uniform amount of the plastisol 24 to the base coat 21. Alternatively, the plastisol 24 may be applied to the base coat 21 by an extrusion process or by laminating.
After the spaced pattern of the final abrasion resistant coat 24 is applied to the base coat 21, the fabric moves through a curing oven where the continuous base coat 21 and spaced abrasion resistant coat 24 are fused at 400 degrees Fahrenheit for two minutes.
The resulting fabric is both abrasion resistant and flexible to an extent not heretofore known in the prior art. Although the invention is described in the environment of a dock shelter fabric, it is to be understood that the utility of the invention is not limited to dock shelter fabrics and it may be used in any environment requiring flexibility and abrasion resistance. Suggested uses are truck tarpaulins, dock shelters, dock pads and tents.
Although specific terms have been employed in the specification, they are used in a generic sense for purposes of illustration and not as a limitation. | A dock shelter fabric comprising a core fabric formed from synthetic fibers, a base coat of polymeric material extending continuously over at least the one surface of the core fabric intended to be exposed to abrasion, and a second polymeric coating of abrasion resistant polymeric material fused in a discontinuous pattern to the continuous surface of the base coat; whereby the discontinuous coating resists abrasion without sacrificing flexibility of the fabric. | 3 |
This is a continuation application of copending application Ser. No. 13/047,061 filed on Mar. 14, 2011; which is a continuation of application Ser. No. 11/742,668 filed on May 1, 2007 and issued Apr. 19, 2011 as patent 7,926,589; which is a continuation of application Ser. No. 11/168,814 filed on Jun. 28, 2005 and issued Jun. 5, 2007 as Pat. No. 7,225,885; which is a continuation of application Ser. No. 09/898,989 filed on Jul. 3, 2001 and issued Aug. 30, 2005 as Pat. No. 6,935,439; which is a continuation of application Ser. No. 09/562,503 filed on May 1, 2000 and issued Aug. 28, 2001 as Pat. No. 6,279,668; which is a continuation of application 09/066,964 filed on Apr. 27, 1998 and issued Jun. 27, 2000 as Pat. No. 6,079,506; the disclosures of which are incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to underground boring tool guidance and, more particularly, to a remote walk over locator/controller configured for determining the underground location of a boring tool and for remotely issuing control commands to a drill rig which is operating the boring tool.
Installing underground utility cable using a steerable boring tool is well known in the art. Various examples are described in U.S. Pat. Nos. 5,155,442, 5,337,002, 5,444,382 and 5,633,589 as issued to Mercer et al (collectively referred to herein as the Mercer Patents), all of which are incorporated herein by reference. An example of the prior art Mercer technique is best illustrated in FIG. 1 herein which corresponds to FIG. 2 in the Mercer Patents. For purposes of clarity, the reference numerals used in the Mercer Patents have been retained herein for like components.
As seen in FIG. 1 , an overall boring machine 24 is positioned within a starting pit 22 and includes a length of drill pipe 10 , the front end of which is connected to the back end of a steerable boring head or tool 28 . As described in the Mercer Patents, the boring tool includes a transmitter for emitting a dipole magnetic field 12 which radiates in front of, behind and around the boring tool, as illustrated in part in FIG. 1 . A first operator 20 positioned at the starting pit 22 is responsible for operating the boring machine 24 ; that is, he or she causes the machine to let out the drill pipe, causing it to push the boring tool forward. At the same time, operator 20 is responsible for steering the boring tool through the ground. A second locator/monitor operator 26 is responsible for locating boring tool 28 using a locator or receiver 36 . The boring tool is shown in FIG. 1 being guided beneath an obstacle 30 . The locator/monitor operator 26 holds locator 36 and uses it to locate a surface position above tool head 28 . Once operator 26 finds this position, the locator 36 is used to determine the depth of tool head 28 . Using the particular locator of the present invention, operator 26 can also determine roll orientation and other information such as yaw and pitch. This information is passed on to operator 20 who then may use it to steer the boring tool to its target. Unfortunately, this arrangement requires at least two operators in order to manage the drilling operation, as will be discussed further.
Still referring to FIG. 1 , current operation of horizontal directional drilling (HDD) with a walkover locating system requires a minimum of two skilled operators to perform the drilling operation. As described, one operator runs the drill rig and the other operator tracks the progress of the boring tool and determines the commands necessary to keep the drill on a planned course. In the past, communication between the two operators has been accomplished using walkie-talkies. Sometimes hand signals are used on the shorter drill runs. However, in either instance, there is often confusion. Because an operating drill rig is typically quite noisy, the rig noise can make it difficult, if not impossible, to hear the voice communications provided via walkie-talkie. Moreover, both the walkie-talkie and the hand signals are awkward since the operator of the drill rig at many times has both of his hands engaged in operation of the drill rig. Confused steering direction can result in the drill being misdirected, sometimes with disastrous results.
The present invention provides a highly advantageous boring tool control arrangement in which an operator uses a walk-over locator unit that is configured for remotely issuing control commands to a drill rig. In this way, problems associated with reliable communications between two operators are eliminated. In addition, other advantages are provided, as will be described hereinafter.
SUMMARY OF THE INVENTION
As will be described in more detail hereinafter, there is disclosed herein a locator/control arrangement for locating and controlling underground movement of a boring tool which is operated from a drill rig. An associated method is also disclosed. The boring tool includes means for emitting a locating signal. In accordance with the present invention, the locator/control arrangement includes a portable device for generating certain information about the position of the boring tool in response to and using the locating signal. In addition to this means for generating certain information about the position of the boring tool, the portable device also includes means for generating command signals in view of this certain information and for transmitting the command signals to the drill rig. Means located at the drill rig then receives the command signals whereby the command signals can be used to control the boring tool.
In accordance with one aspect of the present invention, the means located at the drill rig for receiving the command signals may include means for indicating the command signals to a drill rig operator.
In accordance with another aspect of the present invention, the means located at the drill rig for receiving the command signals may include means for automatically executing the command signals at the drill rig in a way which eliminates the need for a drill rig operator.
In accordance with still another aspect of the present invention, drill rig monitoring means may be provided for monitoring particular operational parameters of the drill rig. In response to the particular operational parameters, certain data may be generated which may include a warning that one of the parameters has violated an acceptable operating value for that parameter. In one feature, the certain data regarding the operational parameters may be displayed at the drill rig. In another feature, the certain data regarding the operational parameters may be displayed on the portable device. The latter feature is highly advantageous in embodiments of the invention which contemplate elimination of the need for a drill rig operator.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be understood by reference to the following detailed description taken in conjunction with the drawings, in which:
FIG. 1 is a partially broken away elevational and perspective view of a boring operation described in the previously recited Mercer Patents.
FIG. 2 is an elevational view of a boring operation being performed in accordance with the present invention in which a portable locator/controller is used.
FIG. 3 is a diagrammatic perspective view of the portable locator/controller which is used in the boring operation of FIG. 2 , shown here to illustrate details of its construction.
FIG. 4 is a partial block diagram illustrating details relating to the configuration and operation of the portable locator/controller of FIG. 3 .
FIG. 5 is a partial block diagram illustrating details relating to the configuration and operation of one arrangement of components located at the drill rig for receiving command signals transmitted from the portable locator/controller of the present invention.
FIG. 6 is a partial block diagram illustrating details relating to the configuration and operation of another arrangement of components located at the drill rig for receiving command signals transmitted from the portable locator/controller and for, thereafter, executing the commands signals so as to eliminate the need for a drill rig operator.
DETAILED DESCRIPTION OF THE INVENTION
Turning again to the drawings, attention is immediately directed to FIG. 2 which illustrates a horizontal boring operation being performed using a boring/drilling system generally indicated by the reference numeral 70 . The drilling operation is performed in a region of ground 72 including a boulder 74 . The surface of the ground is indicated by reference numeral 76 .
System 70 includes a drill rig 78 having a carriage 80 received for movement along the length of an opposing pair of rails 82 which are, in turn, mounted on a frame 84 . A conventional arrangement (not shown) is provided for moving carriage 80 along rails 82 . During drilling, carriage 80 pushes a drill string 86 into the ground and, further, is configured for rotating the drill string while pushing, as will be described. The drill string is made up of a series of individual drill string sections or pipes 88 , each of which includes a suitable length such as, for example, ten feet. Therefore, during drilling, sections 88 must be added to the drill string as it is extended or removed from the drill string as it is retracted. In this regard, drill rig 78 may be configured for automatically adding or removing the drill string sections as needed during the drilling operation. Underground bending of the drill string sections enables steering, but has been exaggerated for illustrative purposes.
Still referring to FIG. 2 , a boring tool 90 includes an asymmetric face 92 and is attached to the end of drill string 86 . Steering of the boring tool is accomplished by orienting face 92 of the boring tool (using the drill string) such that the boring tool is deflected in the desired direction. Boring tool 90 includes a mono-axial antenna such as a dipole antenna 94 which is driven by a transmitter 96 so that a magnetic locating signal 98 is emanated from antenna 94 . Power may be supplied to transmitter 96 from a set of batteries 100 via a power supply 102 . A control console 104 is provided for use in controlling and/or monitoring the drill rig. The control console includes a drill rig telemetry transceiver 106 connected with a telemetry receiving antenna 108 , a display screen 110 , an input device such as a keyboard 112 , a processor 114 , and a plurality of control levers 116 which, for example, hydraulically control movement of carriage 80 along with other relevant functions of drill rig operation.
Still referring to FIG. 2 , in accordance with the present invention, drilling system 70 includes a portable locator/controller 140 held by an operator 141 . With exceptions to be noted, locator 140 may be essentially identical to locator 36 , as described in the Mercer Patents.
Turning to FIG. 3 in conjunction with FIG. 2 , the same reference numerals used to describe locator 36 in the Mercer Patents have been used to designate corresponding components in locator/controller 140 . In order to understand and appreciate the present invention, the only particular components of locator 36 that form part of locator 140 and that are important to note here are the antenna receiver arrangement comprised of orthogonal antennas 122 and 124 and associated processing circuitry for measuring and suitably processing the field intensity at each antenna and roll/pitch antenna 126 and associated processing circuitry 128 for measuring the pitch and roll of the boring tool. Inasmuch as the Mercer patents fully describe the process by which locator 140 is used to find the position of boring tool 90 , the reader is referred to the patents for a detailed description of the locating method.
Referring to FIGS. 2-4 , in accordance with the present invention, locator/controller 140 includes a CPU 144 , interfaced with a remote telemetry transceiver 146 , a joystick 148 and a display 150 . Remote transceiver 146 is configured for two-way communication with drill rig transceiver 106 via an antenna 152 . Joystick 148 is positioned in a convenient location for actuation by operator 141 . In accordance with one highly advantageous feature of the present invention, operator 141 is able to remotely issue control commands to drill rig 78 by actuating joystick 148 . Commands which may be issued to the drill rig by the operator include, but are not limited to (1) roll orientation for steering direction purposes, (2) “advance” and (3) “retract.” It should be appreciated that the ability to issue these commands from locator/controller 140 , in essence, provides for complete boring tool locating and control capability from locator/controller 140 . A locator/controller command is implemented using CPU 144 to read operator actuations of the joystick, interpret these actuations to establish the operator's intended command, and then transfer the command to remote transceiver 146 for transmission to the command drill rig telemetry transceiver 106 at the drill rig, as will be described immediately hereinafter.
Still referring FIGS. 2-4 , control commands are entered by using display 150 in conjunction with joystick 148 . Display 150 includes an enhanced roll orientation/steering display 154 having a clock face 156 which shows clock positions 1 through 12. These clock positions represent the possible steering directions in which boring tool 90 may be set to travel. That is, the axis of the boring tool is assumed to extend through a center position 158 of the clock display and perpendicular to the plane of the figure. The desired roll orientation is established by moving joystick 148 either to the left or right. As the joystick is moved, a desired roll orientation pointer 160 incrementally and sequentially moves between the clock positions. For instance, if the desired roll pointer was initially located at the 12 o'clock position (not shown), the locator/controller operator may begin moving it to the 3 o'clock position by moving and holding the joystick to the right. CPU 144 detects the position of the joystick and incrementally moves the desired roll pointer to the 1 o'clock, then 2 o'clock, and finally the 3 o'clock position. At this point, the operator releases the joystick. Of course, at the 3 o'clock position, the command established is to steer the boring tool to the right. Similarly, the 6 o'clock position corresponds to steering downward, the 9 o'clock position corresponds to steering to the left and the 12 o'clock position corresponds to steering upward. As mentioned previously, steering is accomplished by setting face 92 of the boring tool in an appropriate position in accordance with the desired roll of the boring tool. With regard to boring tool steering, it is to be understood that boring tool steering has been implemented using concepts other than that of roll orientation and that the present invention is readily adaptable to any steering method either used in the prior art or to be developed.
Having established a desired steering direction, operator 141 monitors an actual roll orientation indicator 162 . As described in the Mercer patents, roll orientation may be measured within the boring tool by a roll sensor (not shown). The measured roll orientation may then be encoded or impressed upon locating signal 98 and received by locator/controller 140 using antenna 126 . This information is input to CPU 144 as part of the “Locator Signal Data” indicated in FIG. 4 . CPU 144 then causes the measured/actual roll orientation to be displayed by actual roll orientation indicator 162 . In the present example, operator 141 can see that the actual roll orientation is at the 2 o'clock position. Once the desired roll orientation matches the actual roll orientation, the operator will issue an advance command by moving joystick 148 forward. Advancement or retraction commands for the boring tool can only be maintained by continuously holding the joystick in the fore or aft positions. That is, a stop command is issued when joystick 148 is returned to its center position. If the locating receiver were accidentally dropped, the joystick would be released and drilling would be halted. This auto-stop feature will be further described in conjunction with a description of components which are located at the drill rig.
Still referring to FIGS. 2-4 , a drill string status display 164 indicates whether the drill rig is pushing on the drill string, retracting it or applying no force at all. Information for presentation of drill string status display 164 along with other information to be described is transmitted from transceiver 106 at the drill rig and to transceiver 146 in the locator/controller. Once the boring tool is headed in a direction which is along a desired path, operator 141 can command the boring tool to proceed straight. As previously described, for straight drilling, the drill string rotates. In the present example, after having turned the boring tool sufficiently to the right, the operator may issue a drill straight command by moving joystick 148 to the left and, thereafter, immediately back to the right. These actuations are monitored by CPU 144 . In this regard, it should be appreciated that CPU 144 may respond to any suitable and recognizable gesture for purposes of issuance of the drill straight command or, for that matter, CPU 144 may respond to other gestures to be associated with other desired commands. In response to recognition of the drill straight gesture, CPU 144 issues a command to be transmitted to the drill rig which causes the drill string to rotate during advancement. At the same time, CPU 144 extinguishes desired roll orientation indicator 160 and actual roll orientation indicator 162 . In place of the roll orientation indicators, a straight ahead indication 170 is presented at the center of the clock display which rotates in a direction indicated by an arrow 172 . It is noted that the straight ahead indication is not displayed in the presence of steering operations which utilize the desired or actual roll orientation indicators. Alternatively, in order to initiate straight drilling, the locator/controller operator may move the joystick to the left. In response, CPU 144 will sequentially move desired roll indicator 160 from the 3 o'clock position, to the 2 o'clock position and back to the 1 o'clock position. Thereafter, the desired roll indicator is extinguished and straight ahead indication 170 is provided. Should the operator continue to hold the joystick to the left, the 12 o'clock desired roll orientation (i.e., steer upward) would next be presented.
In addition to the features already described, display 150 on the locator/controller of the present invention may include a drill rig status display 174 which presents certain information transmitted via telemetry from the drill rig to the locator/controller. The drill rig status display and its purpose will be described at an appropriate point below. For the moment, it should be appreciated that commands transmitted to drill rig 78 from locator/controller 140 may be utilized in several different ways at the drill rig, as will be described immediately hereinafter.
Attention is now directed to FIGS. 2 and 5 . FIG. 5 illustrates a first arrangement of components which are located at the drill rig in accordance with the present invention. As described, two-way communications are established by the telemetry link formed between transceiver 106 at the drill rig and transceiver 146 at locator/controller 140 . In this first component arrangement, display 110 at the drill rig displays the aforedescribed commands issued from locator/controller 140 such that a drill rig stationed operator (not shown) may perform the commands. Display 110 , therefore, is essentially identical to display 150 on the locator/controller except that additional indications are shown. Specifically, a push or forward indication 180 , a stop indication 182 and a reverse or retract indication 184 are provided. It is now appropriate to note that implementation of the aforedescribed auto-stop feature should be accomplished in a fail-safe manner. In addition to issuing a stop indication when joystick 148 is returned to its center position, the drill rig may require periodic updates and if the updates were not timely, stop indication 182 may be displayed automatically. Such updates would account for loss of the telemetry link between the locator/controller and the drill rig.
Still referring to FIGS. 2 and 5 , the forward, stop and retract command indications eliminate the need for other forms of communication between the drill rig operator and the locator/controller operator such as the walkie-talkies which were typically used in the prior art. At the same time, it should be appreciated that each time a new command is issued from the locator/controller, an audible signal may be provided to the drill rig operator such that the new command does not go unnoticed. Of course, the drill rig operator must also respond to roll commands according to roll orientation display 154 by setting the roll of the boring tool to the desired setting. In this regard, it should be mentioned that a second arrangement (not shown) of components at the drill rig may be implemented with a transmitter at the locator/controller in place of transceiver 146 and a receiver at the drill rig in place of transceiver 106 so as to establish a one-way telemetry link from the boring tool to the drill rig. However, in this instance, features such as operations status display 174 and drill string status display 164 cannot be provided at the locator/controller.
It should be appreciated that the first and second component arrangements described with regard to FIG. 5 contemplate that the drill rig operator may perform tasks including adding or removing drill pipe sections 88 from the drill string and monitoring certain operational aspects of the operation of the drill rig. For example, the drill rig operator should insure that drilling mud (not shown) is continuously supplied to the boring tool so that the boring tool does not overheat whereby the electronics packaged housed therein would be damaged. Drilling mud may be monitored by the drill rig operator using a pressure gauge or a flow gauge. As another example, the drill rig operator may monitor the push force being applied to the drill string by the drill rig. In the past, push force was monitored by “feel” (i.e., reaction of the drill rig upon pushing). However, push force may be directly measured, for instance, using a pressure or force gauge. If push force becomes excessive as a result of encountering an underground obstacle, the boring tool or drill string may be damaged. As a final example, the drill rig operator may monitor any parameters impressed upon locating signal 98 such as, for instance, boring tool temperature, battery status, roll, pitch and proximity to an underground utility. In this latter regard, the reader is referred to U.S. Pat. No. 5,757,190 entitled A SYSTEM INCLUDING AN ARRANGEMENT FOR TRACKING THE POSITIONAL RELATIONSHIP BETWEEN A BORING TOOL AND ONE OR MORE BURIED LINES AND METHOD which is incorporated herein by reference.
Referring to FIG. 5 , another feature may be incorporated in the first and second component arrangements which is not requirement, but which nonetheless is highly advantageous with regard to drill rig status monitoring performed by the drill rig operator. Specifically, a rig monitor section 190 may be included for monitoring the aforementioned operational parameters such as drilling mud, push force and any other parameters of interest. As previously described, proper monitoring of these parameters is critical since catastrophic equipment failures or damage to underground utilities can occur when these parameters are out of range. In accordance with this feature, processor 114 receives the status of the various parameters being monitored by the rig monitor section and may provide for visual and/or aural indications of each parameter. Visual display occurs on operations status display 174 . The display may provide real time indications of the status of each parameter such as “OK”, as shown for drilling mud and push force, or an actual reading may be shown as indicated for the “Boring Tool Temperature”. Of course, visual warnings in place of “OK” may be provided such as, for example, when excessive push force is detected. Audio warning may be provided by an alarm 192 in the event that threshold limits of any of the monitored parameters are violated. In fact, the audio alarm may vary in character depending upon the particular warning being provided. It should be mentioned that with the two-way telemetry link between the drill rig and locator/controller according to the aforedescribed first component arrangement, displays 164 and 174 may advantageously form part of overall display 150 on locator/controller 140 , as shown in FIG. 4 , which may also include alarm 192 . However, such operational status displays on the locator/controller are considered as optional in this instance since the relevant parameters may be monitored by the drill rig operator. The full advantages of rig monitor section 190 and associated operations status display 174 will come to light in conjunction with a description of a fully automated arrangement to be described immediately hereinafter.
Referring to FIGS. 2 and 6 , in accordance with a third, fully automated arrangement of the present invention, a drill rig control module 200 is provided at drill rig 78 . Drill rig control module 200 is interfaced with processor 114 . In response to commands received from locator/controller 140 , processor 114 provides command signals to the drill rig control module. The latter is, in turn, interfaced with drill rig controls 116 such that all required functions may be actuated by the drill rig control module. Any suitable type of actuator (not shown) may be utilized for actuation of the drill rig controls. In fact, manual levers may be eliminated altogether in favor of actuators. Moreover, the actuators may be distributed on the drill rig to the positions at which they interface with the drill rig mechanism. For reasons which will become apparent, this third arrangement requires two-way telemetry between the drill rig and locator/controller such that drill string status display 164 and operations status display 174 are provided as part of display 150 on the locator/controller. At the same time, these status displays are optional on display 110 at the drill rig.
Still referring to FIGS. 2 and 6 , in accordance with the present invention, using locator/controller 140 , operator 141 is able to issue control commands which are executed by the arrangement of FIG. 6 at the drill rig. Concurrent with locating and controlling the boring tool, operator 141 is able to monitor the status of the drill rig using display 150 on the locator/controller. In this regard, display 174 on the locator/controller also apprises the operator of automated drill rod loading or unloading with indications such as, for example, “Adding Drill Pipe.” In this manner, the operator is informed of reasons for normal delays associated with drill string operations. Since push force applied by the drill rig to the drill string is a quite critical parameter, the present invention contemplates a feature (not shown) in which push force is measured at the drill rig and, thereafter, used to provide push force feedback to the operator via joystick 148 for ease in monitoring this critical parameter. The present invention contemplates that this force feedback feature may be implemented by one of ordinary skill in the art in view of the teaching provided herein. Still other parameters may be monitored at the drill rig and transmitted to locator/controller 140 . In fact, virtually anything computed or measured at the drill rig may be transmitted to the locator/controller. For example, locator/controller 140 may display (not shown) deviation from a desired path. Path deviation data may be obtained, for example, as set forth in U.S. Pat. No. 5,698,981 entitled BORING TECHNIQUE which is incorporated herein by reference. Alternatively, path deviation data may be obtained by using a magnetometer (not shown) positioned in the boring tool in combination with measuring extension of the drill string. With data concerning the actual path taken by the boring tool, the actual path can be examined for conformance with minimum bend radius requirements including those of the drill string or those of the utility line which, ultimately, is to be pulled through the completed bore. That is, the drill string or utility line can be bent too sharply and may, consequently, suffer damage. If minimum bend radius requirements for either the drill string or utility are about to be violated, an appropriate warning may be transmitted to locator/controller 140 . It should be appreciated that with the addition of the drill rig control module, complete remote operation capability has been provided. In and by itself, it is submitted that integrated locating capability and remote control of a boring tool has not been seen heretofore and is highly advantageous. When coupled with remote drill rig status monitoring capability, the present invention provides remarkable advantages over prior art horizontal directional drilling systems.
The advantages of the fully automated embodiment of the present invention essentially eliminate the need for a skilled drill rig operator. In this regard, it should be appreciated that the operator of a walkover locator is, in most cases, knowledgeable with respect to all aspects of drill rig operations. That is, most walkover locator operators have been trained as drill rig operators and then advance to the position of operating walkover locating devices. Therefore, such walkover locator operators are well versed in drill rig operation and welcome the capabilities provided by the present invention.
It should be understood that an arrangement for remotely controlling and tracking an underground boring tool may be embodied in many other specific forms and produced by other methods without departing from the spirit or scope of the present invention. Therefore, the present examples are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims. | A drilling system performs underground boring using a drill rig and a boring tool which is configured for moving through the ground under control of the drill rig to form an underground bore. A monitoring arrangement, forming part of the system, includes a detection arrangement at the drill rig for monitoring at least one operational parameter to produce a data signal relating to at least one of a utility to be installed in the underground bore, the drill rig and the boring tool. A portable device forms another part of the system for receiving the data signal relating to the operational parameter for use by the portable device. A communication arrangement, for example using telemetry, transfers the data signal from the drill rig to the portable device. The operational parameter may be monitored for the purpose of preventing equipment failure. | 4 |
RELATED APPLICATIONS
The present application is a Divisional of U.S. patent application Ser. No. 09/897,013, filed on Jul. 3, 2001, which claims priority from U.S. Provisional Patent Application No. 60/259,228, filed on Jan. 3, 2001.
FIELD OF THE INVENTION
The present invention relates generally to the field of digital copyright protection. More specifically, the present invention deals with identification of and active/reactive protection measures against copyright infringement of digital media in digital file sharing networks and publicly accessible distribution systems.
BACKGROUND OF THE INVENTION
File sharing systems and other publicly accessible distribution systems over the Internet are often used for distribution of copyright protected content, such distribution often comprises infringement of copyright protection laws. Such illegal or unauthorized distribution cause financial damages to the lawful content owners. It is therefore of great interest to find a method that may stop or at least reduce such acts without, at the same time, interfering with the lawful use of such systems.
Methods for copyright enforcement over digitally distributed media in file distribution and sharing systems are known. Some of the known methods are only affective for providing protection against centralized file sharing systems, where locating desired content is aided by a central server or servers providing the service. (e.g., the “Napster” file sharing service). In such a case, software on such central servers may monitor information exchange, and thereby prohibit illegal or unauthorized use. Such methods require the cooperation of the service operator or administrator. However, protection of copyrighted content delivered through decentralized distribution systems (some times known as “peer to peer” networks—e.g., “Gnutella”, “FreeNet”, “Usenet” etc’), as well as protection of copyrighted content in centralized file sharing services without the cooperation of the service operator or administrator, is much harder, and these problems are not addressed by current legal or technological methods. It is foreseeable that as the availability of disk space and bandwidth for data communication increases, illegal or unauthorized distribution of video and audio content may become prevalent unless effective counter-measures are available.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention there is provided a system for external monitoring of networked digital file sharing to track predetermined data content, the system comprising:
at least one surveillance element for distribution over the network, the surveillance elements comprising:
search functionality for nodewise searching of the networked digital file sharing and identification functionality associated with the search functionality for identification of the predetermined data content, therewith to determine whether a given file sharing system is distributing the predetermined data content.
Preferably, the search functionality is operable to carry out searching at a low level of a network protocol.
Alternatively or additionally, the search functionality is operable to carry out searching at a high level of a network protocol.
Alternatively or additionally, the search functionality is operable to carry out the searching at an application level.
Preferably, the surveillance element is a first surveillance element in which the search functionality comprises functionality for operating search features of the networked digital file sharing.
Preferably, the identification functionality comprises use of a signature of the predetermined content.
Preferably, the signature comprises a title of the predetermined content.
Preferably, the signature comprises a derivative of a title of the predetermined content.
Preferably, the signature comprises a statistical processing result carried out on the content.
Preferably, the signature comprises a signal processing result carried out on the content.
Preferably, the signature comprises a description of the content.
Preferably, the signature is a derivative of the description of the content.
Preferably, the surveillance element is a second surveillance element and comprises interception functionality for intercepting data transport on the network, and wherein the identification functionality is associated with the interception functionality for finding an indication of the data content within the intercepted data transport.
Preferably, the identification functionality comprises a signature of the predetermined content for comparison with data of the intercepted message to determine whether the message contains the evidence of the data content.
Preferably, the content comprises alphanumeric data and the signature is a derivation of the alphanumeric data.
Preferably, the content comprises binary data and the signature comprises a derivation of the binary data.
Preferably, the derivation is a hash function of the binary data.
Preferably, the derivation is a function of metadata of the content.
Preferably, the signature comprises a title of the data content.
Preferably, the signature comprises a derivative of the title of the data content.
Preferably, the signature comprises a statistical processing result carried out on the content.
Preferably, the signature comprises a signal processing result carried out on the content.
Preferably, the signature comprises a description of the content.
Preferably, the signature comprises a derivative of the description of the content.
Preferably, the surveillance element further comprises input/output functionality for receiving commands from the system and sending results of the search.
Preferably, the system further comprises a co-ordination element for interacting with the distributed input/output functionality to control deployment of the surveillance elements over the network and to monitor results from a plurality of the surveillance elements.
Preferably, the co-ordination element is further operable to interact with reaction elements by providing the reaction elements with details of locations of the predetermined content obtained from the surveillance elements, thereby to prompt the reaction elements to react against the locations.
Preferably, the file sharing comprises a document exchange system and the surveillance element further comprises functionality for representing itself as a host server for the system, thereby to obtain data of documents on the system for the search functionality.
In a particularly preferred embodiment there is additionally provided:
at least two first surveillance elements, each first surveillance element comprising functionality for operating search features of the networked digital file sharing.
at least two second surveillance elements, each the second surveillance element comprising interception functionality for intercepting messaging on the network, and wherein the identification functionality is associated with the interception functionality for identifying evidences of the data content within the intercepted messages, and
at least one control element for deploying the surveillance elements around the network and obtaining search results from the surveillance elements.
Preferably, the surveillance element is a first surveillance element and the search functionality comprises functionality for operating search features of the networked digital file sharing.
Preferably, the identification input functionality is operable to receive input from a comparator associated with a signature holder for holding a signature of the predetermined content, the comparator being operable to compare the content against the signature thereby to indicate to the input functionality the presence of the content.
Preferably, the signature comprises a title of the predetermined content.
Preferably, the signature is a derivative of a title of the predetermined content.
Preferably, the signature comprises a statistical processing result carried out on the content.
Preferably, the signature comprises a signal processing result carried out on the content.
Preferably, the signature comprises a description of the content.
Preferably, the signature comprises a derivative of a description of the content.
Preferably, the surveillance element is a second surveillance element and comprises interception functionality for intercepting messaging on the network, and wherein the identification functionality is associated with the interception functionality for identifying evidences of the data content within the intercepted messages.
Preferably, the search functionality further comprises input/output functionality for receiving commands from the system and sending results of the search.
Preferably, the system further comprises a co-ordination element for interacting with the distributed input/output functionality to control deployment of the surveillance elements over the network and to monitor results from a plurality of the surveillance elements, the co-ordination element further being operable to interact with the attack elements by providing the attack elements with details of locations of the predetermined content obtained from the surveillance elements, thereby to prompt the attack elements to attack the locations.
Preferably, the file sharing comprises a document exchange system and the surveillance element further comprises functionality for representing itself as a host server for the system, thereby to obtain data of the file sharing for the search functionality.
Preferably, the identification functionality is operable to identify items in the document exchange system comprising the predetermined content.
Preferably, the attack element comprises functionality to send to the system a delete command to delete the item throughout the system.
Preferably, the attack element comprises repetitive output functionality for repeatedly sending response requests to the file sharing system.
Preferably, the response request comprises a download request.
The system is preferably operable to co-ordinate response requests between a plurality of attack elements distributed over the network.
The system is preferably operable to co-ordinate download requests between a plurality of the attack elements distributed over the network.
Preferably, the surveillance agent is a third surveillance element, comprising network protocol scan functionality operable to intercept and analyze network communication items of a predetermined network traffic, thereby to find protected content in transport.
The system preferably comprises at least one attack element, wherein the attack functionality is operable to utilize features of the file sharing in the attack
A preferred embodiment comprises at least one attack element wherein the attack functionality comprises transport interference functionality for interfering with messaging over the network.
Preferably, the transport interference functionality comprises exchange functionality for exchanging the predetermined message content in the messaging with other message content.
Preferred embodiment additionally or alternatively comprise:
at least two first surveillance elements, each first search element comprising functionality for operating search features of the networked digital file sharing,
at least two second surveillance elements, each the second surveillance element comprising interception functionality for intercepting messaging on the network, and wherein the identification functionality is associated with the interception functionality for identifying evidences of the data content within the intercepted messages,
at least two of the attack elements, and
at least one control element for distributing the surveillance and attack elements around the network, obtaining surveillance results from the surveillance elements, and coordinating activity of the attack elements to carry out a coordinated multiple point attack on the file sharing system.
According to a second aspect of the present invention there is provided a system for external monitoring and control of networked digital file sharing to track predetermined data content and limit distribution thereof, the system comprising:
at least one surveillance element for distribution over the network, the surveillance element comprising:
surveillance functionality for searching the digital file sharing and identification input functionality associated with the search functionality for receiving an indication of the presence of the predetermined content, and at least one attack element, comprising:
input functionality for receiving identification data of a file sharing system found to be distributing the predetermined content, and attack functionality for applying an attack to the file sharing system to reduce the file sharing system's ability to distribute the predetermined data content.
According to a third aspect of the present invention there is provided a network external content distribution control system comprising:
network content identification functionality for identifying predetermined content distributed over a digital file sharing network, the network comprising a plurality of nodes, and
network attack functionality for applying an attack over the digital file sharing network, the attack being directable to reduce the ability of the network to distribute the identified content.
Preferably, at least one of the nodes is identified to have the predetermined content, and at least one of the nodes being identified as a distribution node of the network, the attack being directable at the distribution node.
According to a fourth aspect of the present invention there is provided a network external content distribution control system comprising at least one surveillance unit for exploring a network to determine at least one of a presence and a distribution pattern of predetermined content and for reporting the determination for remote analysis.
According to a fifth aspect of the present invention there is provided a network scanning element for use in a network external content distribution control system, the scanning element being operable to scan at least a portion of a network suspected of distributing predetermined content by connecting to available ports in the network portion, via the port connections to determine the presence of network nodes participating in the distribution.
According to a sixth aspect of the present invention there is provided a method of externally scanning a distributed network comprising a plurality of nodes, to search for predetermined content available for distribution from the nodes, the method comprising:
distributing at least one surveillance element to the network, the surveillance element comprising:
search functionality for nodewise searching of the networked digital file sharing and
identification functionality associated with the search functionality for identification of the predetermined data content, therewith to determine whether a given file sharing system is distributing the predetermined data content.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the appended drawings in which:
FIG. 1 is a simplified block diagram of a first preferred embodiment of the present invention showing a surveillance subsystem and a countermeasures subsystem;
FIG. 2 is a simplified block diagram of the embodiment of FIG. 1 in greater detail, showing elements of the subsystems of FIG. 1 ;
FIG. 3 is an illustration of the topology of decentralized peer-to-peer file sharing system such as “Gnutella”, together with the position of the system elements;
FIG. 4 is an illustration of an initiated search by “surveillance element”;
FIG. 5 is an illustration of a simple denial of service (DoS) attack, based on sending multiple “syn” messages against a distributor of illegal or unauthorized content;
FIG. 6 is an illustration of another simple denial of service (DoS) attack, based on multiple requests, in short time intervals, to make connections;
FIG. 7 is an example of another possible action against the illegal or unauthorized distributor, which is based on simultaneous download of the illegal or unauthorized content using several connections;
FIG. 8 is an illustration of a method that allows an attack even in case in which the distributor is protected by a “firewall” software. In this case, the offensive element initiate a “push” request using methods that are supplied by the file sharing system, thereby causing the distributor to establish a file “push” initiative (e.g., HTTP connection) with the offensive element;
FIG. 9 is an illustration of the usage of an intrusive surveillance element, which scans communication protocols such as Internet Protocol in order to find illegal or unauthorized content in transport;
FIG. 10 is an illustration of a method to reduce the desirability of illegal or unauthorized usage of file sharing systems by replaying to requests for an illegal or unauthorized content by sending versions of the content that may not satisfy the user;
FIG. 11 is an illustration of two search methods for illegal or unauthorized content in a newsgroup; and
FIG. 12 is an illustration of two methods for canceling newsgroup messages that contain illegal or unauthorized content.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention comprise a method and system for information gathering about the distribution of illegal or unauthorized content in file sharing and distribution systems, and possibly for active reduction of the availability of file sharing and distribution systems for the unauthorized distribution of copyrighted content on publicly accessible networks. The system preferably comprises one or more types of surveillance elements, which accumulate different kinds of information regarding the illegal or unauthorized distribution of copyrighted content over file sharing and distribution systems, as well as other information that may be relevant for attempts to stop or reduce such distribution. The system may also use one or more types of offensive elements, which may attempt to stop or reduce the illegal or unauthorized distribution once the possible or actual existence of such an act is detected. The above elements may be physically separated, thereby increasing the robustness of the system against counter-counter measures. The identification of the illegal or unauthorized content is executed inside a surveillance element, and may be based on alphanumeric data, such as the possible variants of its title and/or a derivative of its title and/or description, and/or on “signatures” of binary files (e.g., a “hash function” of the binary file or parts thereof) and/or on the properties of the content as video and/or as audio signal and/or as a textual content (e.g., methods that are based on the identification of a signature indicating the content), or on meta data included with the content (such as ID3 tags). Once illegal or unauthorized distribution of content via a certain file sharing system and/or newsgroup is detected, by one or more of the surveillance elements, the system may use offensive elements in order to attempt to interfere with the illegal or unauthorized activities. The offensive elements may use specific features and known vulnerabilities of the file sharing and distribution systems and/or vulnerabilities in the infrastructures such systems depend upon. In particular, the present disclosure describes several methods that can be used against illegal file distribution in decentralized, peer-to-peer file sharing system, such as “Gnutella”, and against the document distribution network commonly referred to as “Internet newsgroups”.
The present embodiments provide a method and system that can be used in order to monitor and/or reduce or eliminate the use of file-sharing networks and/or newsgroups for illegal content distribution in computer networks such as the Internet. The embodiments may be used to supplement a secure content distribution system, e.g. a video or audio-on demand system operating over the Internet or other network.
Reference is now made to FIG. 1 , which is a simplified block diagram showing a system according to a first preferred embodiment of the present invention. A network content distribution surveillance and reaction system 10 comprises two subsystems 12 and 14 , the first of which 12 is a surveillance subsystem for carrying out surveillance of the file-sharing network and document distribution system. The surveillance subsystem preferably makes use of surveillance elements, as referred to above, to gather data about the various content items that are available. The second subsystem 14 is a countermeasure subsystem comprising the offensive or attack elements referred to above, which are able to take various active steps in order to reduce or eliminate illegal content distribution.
Reference is now made to FIG. 2 , which is a simplified block diagram showing the two subsystems of FIG. 1 in greater detail. In FIG. 2 , the system is shown to comprise a series of elements for use together. One such element, referred to hereinbelow as a first surveillance element 16 , is preferably a network application that appears as a regular agent or client of the file-sharing network. The surveillance elements preferably perform a search for to-be-protected content, specifically using tools that the file-sharing system supplies for such a search. The surveillance elements may use a polymorphic search, possibly in several languages and/or several cinematic cuts and/or several audio mixing sessions in order to cover the various forms in which the content names or descriptors may appear. The search for specific content may be obscured using a wider search for innocent content. The search for specific content is referred to hereinbelow as an initiated search. Such an approach takes advantage of one essential property of the file sharing and/or distribution system, that in order to be convenient for users, content has to be easy to find. If the initiated search forces the distribution systems to use less straightforward content names it will have made the illegal material less available to users and will have to some extent achieved its purpose.
If the file-sharing and/or distribution system does not allow searches, and in an attempt to increase the amount of content that it is possible to detect, an attempt to guess content names is preferably made, using methods such as the so-called dictionary attack, based on the name of the protected content and/or an attempt to crawl the file-sharing content space using various methods provided by the file sharing network, and/or crawling or searching other locations or networks which may refer to content in the aforementioned file-sharing system. The method will be described in greater detail below.
Additional elements 18 , referred to as second surveillance elements preferably perform a search that is based on an analysis of data being transported, for example query data or data being downloaded, between other elements in the network. Such a transport analysis type of search is referred to hereinbelow as a transport search. The second surveillance elements preferably use high-performance computers, with wide bandwidth and disc space and an optimized connection scheme, in order to process large amounts of traffic and thereby find a large proportion of traffic of illegal content and data relating thereto. The surveillance elements preferably use a polymorphic indexed search based on the content name and\or descriptor (possibly in several languages) and\or a search for a signature of the content, i.e., idiosyncratic properties of the audio and\or video signal, that either exist in the original signal or are added to the original signal as watermarks. Methods for obtaining signatures relating to an earlier search and performing searches are described, e.g., in U.S. Pat. Nos. 6,125,229, 5,870,754 and 5,819,286. Methods for watermark embedding and usage are described, e.g., in U.S. Pat. Nos. 5,960,081, 5,809,139 and 6,131,161. The contents of each of the above documents are hereby incorporated by reference.
A further type of surveillance element is the intrusive surveillance element 20 . Intrusive surveillance elements preferably scan communication protocols such as Internet Protocol in order to find illegal content in transport. If such content is found, the elements can report about the illegal transport to the appropriate authorities, and may interfere with the content transport method and interrupt or cancel the transfer.
The surveillance elements and/or the intrusive surveillance elements may be present or rely on scanning not only of lower levels of the network protocols (such as network data-link and transport) but also of higher levels (up to and including application levels, especially when considering the case of a virtual network whose lower levels are based on the higher level of the basic underlying network. The latter is generally the case in many file sharing networks.
Also there are provided two kinds of offensive elements, internal offensive or attack elements 22 and external offensive elements 24 . Again, the offensive elements are preferably embodied as autonomous agents, able to locate themselves at will over the network. The internal agents 22 are based on file sharing system protocols (often involving client programs) and appear to be nodes of the network. The internal offensive agents 22 preferably use the features of the file sharing system in order to perform various attacks on distributors of illegal content, as will be described in more detail below.
The external offensive elements 24 need not use the file sharing system protocols. External offensive elements 24 may preferably use various types of attacks that may not be possible while using the standard file-sharing network programs.
There are preferably also provided hybrid elements 26 which incorporate various combinations of properties of the above elements.
A further element for incorporation in the system is a system manager or coordinator element 28 . As mentioned above, the elements referred to may be distributed over a network. A unit is thus preferably provided to accumulate the network intelligence data from the surveillance entities, analyze the data, and coordinate required attacks. The coordinator may likewise be provided as an autonomous agent, providing the advantage that the system as a whole is able to center itself anywhere on the network, making it harder for countermeasures to be effective.
Reference is now made to FIG. 3 , which is a simplified block diagram showing a decentralized peer-to-peer file sharing system such as “Gnutella”, and illustrating preferred positions of the system entities. The first two surveillance elements, (A), and (B) perform distributed initiated searches for the content to be protected, while the next two surveillance elements (C) and (D) perform transport searches. In one embodiment of the system, results of the above searches are then returned to the coordinator (E) via a secure channel (dashed arrows pointed to (E)). Elements (F) and (G) are system offensive agents and element (H) is an external offensive element that can perform attacks against (I) (black arrows). The attacks can be coordinated by the coordinator (E) (dashed arrows starting from (E)). In another embodiment of the system, the system elements communicate using a “peer-to-peer” type of communication.
Reference is now made to FIG. 4 , which is a block diagram of the decentralized peer to peer file sharing system of FIG. 3 , illustrating element interaction in an initiated search by the first surveillance element (A). A search query propagates via the system elements to reach a possible distributor of illegal content (I), who replies that he has the content. The search answers prorogate back to (A). (A) then connects to (I) and preferably starts to download the content. (A) may further check that the downloaded content is indeed the required content by comparing a signature of the required content with the signature of the downloaded content.
The information gathered by the surveillance elements (e.g., the details of the replays to its queries) can be used in order to create reports and (possibly) also to inform the interested parties (e.g., via e-mail or web-based interface)
Methods for performing denial of service (DoS) attacks are known, and are regularly performed, (often illegally), against Internet servers. In the context of the present embodiments, DoS attacks are preferably performed against servers of file sharing systems that are involved in illegal digital content piracy, providing that the required legal authorization exists.
Reference is now made to FIG. 5 , which is a simplified timing diagram describing a simple attack that the offensive elements may perform against an illegal content distributor. The attack is a standard “denial of service” (DoS) attack, and is based on multiple “syn” messages with preferably spoofed (forged) IP addresses. As known to the skilled person, a spoofed IP address may be a legal (routable) IP address of a non-existent or otherwise irrelevant network entity. In some file sharing networks, e.g., “Gnutella”, the attacker need not be part of the network. The attack is preferably continued or even increased until (I)'s resources are exhausted.
Reference is now made to FIG. 6 , which is a further timing diagram illustrating another simple DoS attack. The attack is based on multiple requests, in short time intervals, to make connections (e.g., TCP connections) with the distributor (I). The attack again preferably continues until the resources of (I) (e.g., connectivity, CPU, RAM, storage etc.) are exhausted.
Reference is now made to FIG. 7 , which is a network element diagram showing an example of another possible attack against the illegal distributor (I). The attack is based on simultaneous download of the illegal content using several connections (either via a single element or via several coordinated elements). Preferably, the number of simultaneous downloads is such as to saturate the system or, at least, reduce the available resources of (I).
Reference is now made to FIG. 8 , which is a schematic diagram illustrating elements involved in an attack over a firewall. Often the distributor is protected by firewall software, which does not allow the offensive elements to initiate a file “get” (e.g., an HTTP connection able to initiate downloading of the data) with the distributor. In the case of a firewall, the offensive element preferably initiates a “push” request using methods that are supplied by the file sharing system (usually sending the request over a control connection initiated by the server), thereby causing the distributor to initiate the required file transfer with the offensive element (either by opening connection to the offensive element or by transferring the file over existing connections through the firewall). The attack thus takes advantage of the fact that the firewall protection has to leave openings to allow regular functioning of the distribution system.
In another form of attack, at least two separate (and possibly very different) offensive elements may be involved—the one sending the request, and the one receiving the file, either may have other functions in the system (especially the first which may mainly be a surveillance element), where a controlling element may be involved in coordinating the attack
Reference is now made to FIG. 9 , which is a schematic diagram showing how the intrusive surveillance element may be used to carry out transport searches. The illegal distributor generally uses a communication protocol such as the Internet Protocol (IP) in order to send data to a client unit. Preferably, the intrusive surveillance element intercepts and scans data coming from a suspected illegal distributor, using the relevant communication protocols, in order to find illegal transport content. Detection may be based on alphanumeric descriptions of the content it is sought to protect and/or on the audio/video/text signal properties thereof.
Reference is now made to FIG. 10 , which is a simplified schematic diagram showing a method for reducing the desirability to end users of illegal file sharing systems. The method comprises intercepting requests for illegal content and replying to them by sending a version of the content that does not satisfy the user. The versions may be for example defective, of low visual or audio quality, contain large amounts of unwanted material, be totally irrelevant etc. The request is intercepted before it reaches the illegal content provider and thus he does not even know that the request was made. On the other hand the user receives content in reply to his request, which preferably partly corresponds to what he requested, leading him to believe that he downloaded the information from the site to which he addressed his request but that the site provides sub-standard material. The user is thus discouraged from using the source again.
Other possible attacks that may be considered for use in the present embodiments may be based on exploitation of flaws in the clients. For example clients expect data to conform to certain protocol standards and it is possible to intercept requests and send data that does not conform to the relevant protocols. Thus malformed messages that cannot be processed by the client may be considered. Possibilities for malformed messages included messages comprising non null terminated strings, spoof push sources, wrong field size descriptors, malformed get requests (i.e. non numeric file index). Such attacks have the potential to disable the client or seriously disrupt its operation if not anticipated by the programmer.
In some file sharing systems (e.g., “Gnutella”), requests are characterized by identification numbers (“request ID”). In general, nodes in the network will not propagate a request if they have already propagated a request with the same ID. Another possible attack that may be considered for use in the present embodiments may therefore be based on the following method: When an attack element receives a request for illegal content, it propagates a spoofed request with the same ID number, thereby, with some probability, causing some of nodes to neglect the original request. Other similar methods of using spoofed or otherwise fake messages can be used to disrupt some aspects of the network or of a certain node or nodes in it, depending on the specification of the network.
A coordination element or elements may be present which would coordinate such attacks
Another surveillance element which should be considered is a port scanning element—which may scan a given portion of the network, trying to connect to all, or to a subset of the available ports in the network portion, and establish a connection of the file sharing network, trying to discern if there are content sharing nodes in it. This surveillance element may be autonomous or coordinated with other elements
It is observed that the above described system may also accumulate and report or otherwise use data about what is shared and transferred and divulge information about the participating parties, their locations, interests etc. which may be used for decision making, legal marketing or other purposes.)
It is also noted that Artificial Intelligence methods may be used for various needs of such a system (such as methods for recognizing the content and related information—especially text analyzing methods, symbolic logic and some forms of fuzzy logic) and for correlating data gathered to produce more meaningful or valuable information.
Document Distribution Networks
Focusing now on document distribution networks, primary consideration will be given to the Internet Newsgroup document distribution network, since it is widely used for document distribution in infringement of copyright and for illegal distribution of video and audio content. The methods described herein are nevertheless applicable, in whole or in part, to other document distribution networks.
Detection of Illegal Content in Newsgroups
Reference is now made to FIG. 11 , which is a simplified schematic diagram of a newsgroup server client arrangement. Newsgroups are non-proprietary lists of messages placed by individual users and thus it is neither possible nor desirable to attack the newsgroup itself. Rather the target in the case of the newsgroup has to be the individual message containing the illegal content.
Two methods for detection of illegal content in newsgroups are described hereinbelow. In the first method a search client element ( 101 ) according to an embodiment of the present invention logs on to a news server in the same way as a regular client, and builds a listing or carries out downloading of the messages in the groups suspected of delivery of the protected content.
After the messages have been received, they are preferably assembled together to reconstruct (wholly or partly) the original files sent. That is to say, in newsgroups, large files are usually sent by splitting them into much smaller files and generally the material that it is desired to protect tends to be large. The reconstructed file may then be examined by other methods referred to in the present disclosure.
Another method of detecting newsgroup content comprises connecting to the news server in the guise of another news server ( 102 ), and requesting batch delivery of the news groups of interest. Once delivery is complete, the server's spool contains all the messages that belong to the groups requested, where they may undergo composition and analysis as in the first method.
Cancellation of Messages that Contain Illegal Content.
Reference is now made to FIG. 12 . FIG. 12 is a simplified block diagram illustrating how an attack may be launched against illegal content on a newsgroup. Once protected content has been discovered, the system may issue commands to the news server network to delete messages that contain the protected content. The commands are referred to in the art as “cancel message” and are preferably delivered from the client ( 101 ) to the local server (first method) or from the spoof server ( 102 ) to other servers (second method). The news servers network preferably propagates the cancel message as an ordinary network message, each server in turn deleting the protected content when the cancel message arrives.
In order to enhance the effectiveness of the newsgroup attack the cancel messages may be delivered to multiple news servers at the same time, causing a reduction of the time for global propagation of the protected content.
There is thus provided a method and apparatus for automatic external content monitoring and control over computerized networks.
It is appreciated that one or more function of any of the methods described herein may be implemented in a different manner than that shown while not departing from the spirit and scope of the invention.
While the methods and apparatus disclosed herein may or may not have been described with reference to specific hardware or software, the methods and apparatus have been described in a manner sufficient to enable persons having ordinary skill in the art to readily adapt commercially available hardware and software as may be needed to reduce any of the embodiments of the present invention to practice without undue experimentation and using conventional techniques.
It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes both combinations and subcombinations of the various features described hereinabove as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description. | A system for external monitoring of networked digital file sharing to track predetermined data content, the system comprising: at least one surveillance element for deployment over said network, said surveillance elements comprising: surveillance functionality for searching said digital file sharing and identification functionality associated with said search functionality for identification of said predetermined data content, therewith to determine whether a given file sharing system is distributing said predetermined data content. | 6 |
This is a continuation of application Ser. No. 798,104, filed May 18, 1977, now U.S. Pat. No. 4,091,588.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to a system for locking adjacently positioned panels together and for suspending the assembled panels from a supporting member. A wide variety of techniques have been used in the past to install panels to overhead supporting structure, including by way of example, panels which are provided with locking flanges configured such that after the flanges of adjacent panels are aligned one of the panels is rotated relative to the other to lock the panels in place. Clips extending downwardly from the supporting member have sometimes been used to secure the adjacent flanges of the panels to the supporting member. In addition to the foregoing, the panels are sometimes fastened directly to the overhead supporting structure with the use of self-drilling fasteners. With these and other known panel locking systems in mind it is apparent that with the spring action panel interlock of the present invention it is possible to accomplish the following objectives believed to be heretofore unavailable. With the present invention, adjacent panels may be interlocked with only "linear" motion by merely urging the male flange of one panel into engagement within the female flange of an adjacent panel. Thus, the necessity of having to swing one panel over the other, or to use clips, or to pre-drill the support before beginning to assemble the panels, is eliminated. Moreover, with the present invention simple screw-type fasteners may be used to secure the panels to the overhead supporting structure from a position below the structure thus avoiding the necessity of having to work on top of the supporting structure. In addition, with the panel interlock of the present invention only very slight pressure by the hand is necessary to "snap" the interlocking flanges of adjacent panels together. But once assembled, the panels cannot unlock by reverse action under downward pressure since increasing the load on the panels results only in forcing the interlocking flanges into tighter engagement. This procedure of interlocking with only slight pressure while providing a fail-safe system against unlocking is applicable over a wide range of dimensional tolerances thus avoiding the necessity of precise orientation of the components of the interlocking system. Still further, the snap-action panel interlock of the present invention is suitable for use with a reinforcing member positioned between the interlocking flanges of adjacent panels for increasing substantially both the load bearing and spanning capability of the assembled panel system.
The foregoing advantages are accomplished with the spring action panel interlock of the present invention which features a first interlocking female flange of one panel that has a portion which extends from the panel to the supporting member, another portion that extends along the supporting member engaging same such that a fastener can secure this portion directly to the supporting member, and another portion that extends away from the supporting member terminating in an end which is spaced from the other portions of the flange and which is provided with a lip. The other interlocking male flange of an adjacent panel has a portion which extends from the panel and which engages only a part of the corresponding portion of the other flange so as to reduce the friction therebetween permitting longitudinal sliding of adjacent panels, and another portion which extends diagonally backwardly terminating in an end which engages the lip of the other flange. Under increased loading, the interlocked panels are forced into even tighter relationship as a result of the diagonally positioned portion of the male flange being forced into a position generally perpendicular to the remainder of the flange thus causing the end of the male flange to force the lip of the female flange outwardly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end view of one of the panels illustrating the construction of the interlocking flanges formed at each end thereof, and the position of the panel just before being urged upwardly into engagement with the other panel which has been fastened to the supporting member;
FIG. 2 is an end view of the panel snap-fitted in place, and a portion of another panel ready to be urged upwardly into engagement therewith;
FIG. 3 is an end view of the interlocking flanges of adjacent panels illustrating movement of the diagonal portion of the male flange into tighter engagement with the female flange as pressure is applied to the panel;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 5 illustrating the interlocking flanges of adjacent panels with a reinforcing member positioned therebetween to increase the load bearing and spanning capability of the assembled panels; and
FIG. 5 is a perspective view of the interlocking flanges of adjacent panels with the reinforcing member shown in dotted lines positioned only at the central portion of the panels.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The spring action panel interlocking system of the present invention is illustrated in FIGS. 1-2, wherein the reference numerals 10, 12 and 14 designate adjacent panels. The panels 10, 12 may be flat as illustrated in FIGS. 1-3 or curved as designated by the reference numerals 10', 12' in FIG. 4. Each of the panels consists of a wall 16 which may be flat or curved and which ternimates in interlocking flanges 18 and 20. The interlocking flange 18 is provided with a first section 22 that extends outwardly from the wall 16, it being apparent that the section 24 joins the section 22 to the wall 16 such that the section 22 is generally perpendicular to the wall 16. The flange 18 is also provided with a second section 26 that extends outwardly from the section 22 and which is generally perpendicular to the section 22. The flange 18 is also provided with a third section 28 that extends outwardly from the section 26 forming an angle with the section 26 which is approximately 90 degrees. The section 28 terminates in a lip 30. Since each of the panels 10, 12 and 14 is formed of a flexible material, for example, roll formed aluminum, it is apparent that the sections 22, 26 and 28 of the interlocking flange 18 are free to flex, as described hereinafter.
The interlocking flange 20 of each of the panels 10, 12 and 14 is provided with a fourth section 32 which extends outwardly from the wall 16, it being apparent that a section 34 joins the section 32 to the wall 16. A fifth section 36 extends from the section 32 such that the included angle between the sections 32 and 36 is slightly less than 180°. It will be apparent from the foregoing that when the sections 32 and 36 of the male interlocking flange 20 are positioned adjacent the section 22 of the female interlocking flange 18 only portions of the sections 32 and 36 engage the section 22. (See the space between flange sections 22, 32 and 36 in FIG. 2, for example) Each of the interlocking flanges 20 is provided with a sixth section 38 which extends diagonally from the section 36 terminating in a lip 40. It will be apparent from FIG. 2 that when the interlocking flanges 18 and 20 are assembled, the lip 40 of the section 38 engages the point of intersection of the section 28 and lip 30 of the interlocking flange 18.
Installation of the panels will now be described with reference to FIGS. 1-2. It will be apparent from FIG. 1 that the interlocking flange 18 of the panel 10 has been fastened to the overhead beam 42 with the fastener 44 which may, for example, be a self-drilling screw. The installer then positions the interlocking flange 20 of the next panel 12 immediately below the interlocking flange 18 of the mounted panel 10 and pushes upwardly thereon. The pressure of the male interlocking flange 20 against the female interlocking flange 18 causes the section 28 and lip 30 of the interlocking flange 18 to spring outwardly as the diagonal section 38 of the interlocking flange 20 springs downwardly and the sections 32 and 36 of the interlocking flange 20 spring inwardly towards the section 22 of the interlocking flange 18. Eventually, the lip 40 of the male flange 20 passes over the lip 30 of the female flange 18 at which time the sections of the interlocking flanges 18 and 20, as previously described, resume their original position.
It will be apparent that precise alignment of the fronts and rears of adjacent of the panels 10, 12 and 14 is unnecessary since after the interlocking flanges 20 have been inserted within the interlocking flanges 18 adjacent of the panels 10, 12 and 14 may be slided longitudinally relative to each other. Note further that since the sections 32 and 36 of the interlocking flange 20 intersect at an angle slightly less than 180° the result is to reduce the areas of the sections 32 and 36 which engage the section 22 thus reducing friction between the interlocking flanges 18 and 20. Reducing friction, of course, permits ease in longitudinal adjustment of the assembled panels. Moreover, the angular relationship between the sections 32 and 36 of the interlocking flange 20 limits the contact between the sections 32 and 22 to the area generally designated by the reference numeral 46 which results in reducing the tendency of the panels to have a "gap" between the adjacent sections 22 and 32, particularly if one of the sections is bent.
Once the panel 12 is snap-fitted to the panel 10, the interlocking flange 18 of the panel 12 is secured to the overhead beam 42 with the fastener 48, as illustrated in FIG. 2, afterwhich the next panel 14 is secured in place by snapping the male interlocking flange 20 of the panel 14 within the female interlocking flange 18 of the panel 12. It will now be apparent that the fasteners 44 and 48 are hidden from view.
The "fail-safe" feature of the panel interlock of the present invention is illustrated in FIG. 3 wherein the interlocking flanges 18 and 20 of the adjacent panels 10 and 12 are shown in locked position. FIG. 3 illustrates how the interlocking flanges 18 and 20 resist unlocking under downward force F despite the fact that only minimal hand pressure is required to lock the interlocking flanges 18 and 20. When force F is applied to the panel 12 the interlocking flanges 18 and 20 resist unlocking as the interlocking flange 20 is forced into even tighter engagement with the interlocking flange 18, eventually resulting in the section 38 of the flange 20 being forced into a position generally perpendicular to the section 36 thereof and the section 28 and lip 30 of the flange 18 being forced outwardly. Thus, the panel 12 cannot unlock from the panel 10 unless and until the flanges 18 and 20 have distorted beyond that position illustrated in FIG. 3.
With the foregoing in mind, certain of the advantages of the spring action panel interlock of the present inention will be described. The adjacent panels 10, 12 and 14 are interlocked with a simple upward linear motion as distinguished from the swing-over motion that is frequently used. That is, during installation it is only necessary to push the panel upwardly into locking relationship with respect to a panel that has already been assembled. The panels 10, 12 and 14 may be attached to the overhead structure 42 with screw-type fasteners 44 and 48 from below, thus avoiding the necessity of working on top of the overhead supporting structure 42. Only easy hand pressure is required for snapping the interlocking flanges 18 and 20 together. While construction time and effort are significantly reduced, the arrangement of the sections of the interlocking flanges of the invention define a "fail-safe" interlock precluding the unlocking of adjacent interlocking flanges under downward pressure. Still further, after the interlocking flanges 18 and 20 are assembled by snapping in place, the adjacent panels 10, 12 and 14 may be easily moved longitudinally by sliding action because friction has been minimized by the angular relationship of the sections 32 and 36 relative to the section 22.
Turning now to FIGS. 4-5, the reference numeral 50 designates generally a reinforcing member that may be positioned within the interlock previously described for the purpose of increasing both the load bearing and spanning capability of the assembled panels 10 and 12. In this connection, it should be noted that flat bottom panels are not as strong under downward loading as structural type panels of comparable gauge metal. This is true because flat panels have considerably less metal under compression in their upper flange areas than do structural panels. Thus, it is necessary to use substantially heavier gauge metal in flat panels than in structural type panels to obtain equivalent loading capacity. But with reinforcing member 50, which is inserted between the interlocking flanges 18 and 20, it is possible to increase the amount of metal that is in a state of compression under loading and thus significantly increase the potential loading and span capability of a given gauge panel, with the additional economic advantage of not having to increase the gauge of metal throughout the entire panel.
As illustrated in FIG. 4, the reinforcing member 50 consists of a section 52 which is positioned between the sections 32 and 36 of the flange 20 and the section 22 of the flange 18, and a section 54 which extends outwardly from the section 52 and which rests against the section 26 of the flange 18. The section 56 of the reinforcing member 50 extends outwardly from the section 54 and rests in abutting relationship against part of the section 28 of the flange 18. As illustrated in FIG. 4, the sections 54 and 56 may comprise portions of the reinforcing member 50 that are "folded" together.
Moreover, and as illustrated in FIG. 5, it is not necessary to have the reinforcing member 50 extend the entire length of th panels 10 and 12 because under extreme loading the adjacent panels 10 and 12 will fail by compressive buckling of the adjacent flanges 18 and 20 at the center of the span of the panels. Thus, optimum results may be obtained by running the reinforcing member 50 over the center one-half or one-third of the span of the panels 10 and 12. | A paneling system having a supporting member and a plurality of panels each of which is provided at the ends thereof with interlocking flanges, the interlocking flange located at one end of the panel having a portion extending from the panel to the supporting member engaging same and thereafter extending away from the supporting member terminating in an end that is positioned in spaced relationship from the remainder of the flange, a fastener securing the flanges to the supporting member, and wherein the interlocking flange at the other end of the panel has a portion extending from the panel which engages only a part of the corresponding portion of the other interlocking flange extending to a point near the supporting member and thereafter backwardly toward the end of the other interlocking flange terminating in an end which engages the end of the other interlocking flange. | 4 |
FIELD OF THE INVENTION
The present invention pertains to papermaking felts. More particularly, the present invention relates to a method of making papermaker's felts having non-periodic nonuniformities.
BACKGROUND OF THE INVENTION
A papermaker's felt must have a high degree of uniformity. Non-uniformities in the papermaker's felt can cause vibration of a paper machine. If these nonuniformities are periodic as a result of the classical procedures used to manufacture wet felts, it is possible to excite the paper machine at the system's natural frequency or at one of the natural frequencies of the components by simply running at the correct speed.
SUMMARY OF THE INVENTION
The principal object of the invention is to provide a method of producing papermaking felts having non-periodic nonuniformities comprising a carded web of fibers, delivering the web to a cross lapper, gradually varying the width of said web delivered to the cross lapper and lapping a plurality of layers of web onto a receiving conveyor as the receiving convevor moves away from the cross lapper so that the cross lapper deposits fibers at an angle from 91 to 113 degrees to the direction of travel of the receiving conveyor, depending on the width of the final batt and the number of layers of web.
The method and apparatus disclosed herein provide a felt with non-periodic nonuniformities. The width of the web used to produce the felt is limited only by the width of available lapping equipment.
These and various other features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying descriptive nature, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE discloses a perspective view of the novel method and apparatus for producing the non-periodic nonuniformities for the felt which is the subiect of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The method disclosed herein and illustrated in the FIGURE provides a web of fibers 2 which has been carded in a conventional manner on a card system. The width of said web of fibers is varied and only limited by the width of the machinery through which it travels.
The carded web 2 is conveyed to a cross lapper 10. The web travels and is deposited on a receiving conveyor 20 traveling in direction 21 and is rolled onto a wind-up roller 31. The carded web 2 is deposited on the moving conveyor 20 so that the leading edge 3 coming off the cross lapper lies flush with and touches edge 4 of the prior layer.
In the apparatus, the lower cart 15 travels from left to right on the moving conveyor. The web is laid onto the conveyor 20 with the speed of the incoming web and the conveyor adjusted to produce the edge-to-edge contact described above. The layers of web thus deposited are consolidated into a homogeneous sheet of fibers by means conventional to the art for insuring the layers of web are prevented from ply separating in subsequent processing.
The web of fibers 2 is produced with a varying width. The widths are infinitely variable within the ranges available in the machine and in the specific example disclosed herein the width of the web thus formed is variable within the ranges of 60" minimum and 84" maximum.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that variations in form may be made without departing from the spirit and scope of the invention. | A method and an apparatus for avoiding periodic non-uniformities in papermaking felts by varying the width of the web going into a cross lapper. | 3 |
FIELD OF THE INVENTION
This invention relates to the field of microsystems characterization systems, and particularly to microelectromechanical microsystems characterization systems.
BACKGROUND OF THE INVENTION
The present invention comprises a testing and characterization system to provide automated multi-domain measurements of a wide range of microsystem devices in either single chip or wafer format. Unlike electronic devices and integrated circuits in which only lumped electrical parameters are needed for device level modeling, microsystem devices require the precise and simultaneous measurement of multi-domain parameters, often widely dissimilar. In the microelectrical domain, probe stations, waveform generators and current-voltage measurement equipment are all instruments used for modeling and or testing based on lumped electrical circuits. However, they are not capable of providing characterization of the mechanical or fluidic properties common in microsystem devices.
Typical microsystem devices that would benefit from the testing and characterization capabilities of the present invention include present and future devices with vibratory or bistable motion in either the horizontal or vertical direction, fluidic properties, or optical properties. Such devices include but are not limited to accelerometers, diffraction gratings, pumps, gyroscopes, micromirrors, micromicrophones, drive motors. actuators and diaphragms.
Current technology and prior art carried over from electronic device testing tend to provide means for testing a few characteristics of the micros,stem devices, primarily electrical. However, these technologies often lack the ability to characterize the results of the electrical stimulus, i.e. mechanical motion. Similarly, prior art exists that is capable of non-contact examination of the topology of wafers or devices in search of structural defects, but these systems too are incapable of characterizing the mechanical motion or fluidic operation of these wafers or devices. Overall, they lack an overall multi-domain characterization ability that is needed to establish the microsystem devices as viable components suitable for full scale manufacturing.
For example, U.S. Pat. No. 5,773,951 by Markowski and Cosby provides a means of wafer only level electrical probing. As discussed above, this technology is capable of testing and verifying the electrical contacts of the microsystems device, but is unable to characterize the operation resulting from the electrical stimulus.
Similarly, several U.S. patents appear to disclose non-contact surface profiling in the determination of structural defects. These include U.S. Pat. No. 5,127,726 by Moran which provides a high resolution surface inspection system: U.S. Pat. No. 5,105,147 by Karasikov and Ilssar which provides a optical inspection system for wafers; U.S. Pat. No. 4,607,525 by Turner and Roch which provides an air probe for wafer contouring. U.S. Pat. No. 5,526,116 and U.S. Pat. No. 5,671,050 by de Groot which provide an optical means of surface profiling for wafer inspection; and U.S. Pat. No. 5,479,252 by Worster .et al., which provides a confocal laser scanning system for defect detection in wafers. However, these systems often lack the ability to provide electrical stimulus to characterize the resultant surface structure or more importantly, to perform microsystem operation.
OBJECTS OF THE INVENTION
Therefore, it is the object of the invention disclosed herein to provide an integrated testing and characterization system for wafer level microsystem technologies.
It is also an object of the invention to provide an integrated testing and characterization system for die level microsystem technologies.
SUMMARY OF THE INVENTION
The present invention provides an improved microsystems testing system. By identifying specific structures, the user can initiate an automated testing sequence 106 to be implemented on that structure or a series of structures. The integrated control system that governs the present invention automates power supply to the device under test 101 , precision motion control of all components, sensor 134 operation, data processing and data presentation. Therefore operation is autonomous once the microstructure is in place and the testing sequence is specified. The integrated testing system can be used to perform tests on an entire wafer or on a single die.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel are set forth in the associated claims. The invention, however, together with further objects and advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram schematically illustrating the entire integrated system of a preferred embodiment of the invention.
FIG. 2 is a block diagram of the integrated control system architecture of the embodiment of FIG. 1 .
FIG. 3 is a flowchart of the operation of the integrated system of the embodiment of FIG. 1 .
FIG. 4 is a block diagram of an alternative embodiment of the invention in which a vacuum and vacuum control means are added to facilitate vacuum testing.
DETAILED DESCRIPTION
The present invention provides an improved testing system for microsystems technology. The overall goal of the system is to provide a basic means of performing automated tests designed to analyze the performance and characterize the operation of microsystems technology. The testing system can be implemented on wafer or die level microsystems, also know as microelectromechanical systems (MEMS). The testing system is predominantly automated, relying on the device design file 101 used to lay out and ultimately manufacture the wafer based structures to “navigate” the wafer or die. Although the primary application of the testing system is single wafer or die testing, for example in a research and development setting, this system could be incorporated into an assembly line for fully automated manufacturing testing within the scope of the invention and its associated claims.
A preferred embodiment of the invention can best be described with reference to FIG. 1 . Controller 100 receives device design file 101 along input train 104 . Device design file 101 comprises the layout file created to manufacture the wafer, and is used for navigation purposes by the testing system.
Controller 100 also receives testing locations input 102 along input train 104 . In embodiment of FIG. 1, testing locations input 102 comprises software level identification by the user of features and/or structures to be tested. The software level identification takes place in relation to device design file 101 , which as noted above, comprises the layout file/program used to create the structure or a file/program compatible thereto. The testing locations input 102 can be identified by the user, for example, through coordinate input or a cursor/cross-hair based point and click scheme, again, based on the information contained within device design file 101 . The location of the features and/or structures to be tested is stored by controller 100 for implementation in the testing sequence.
Testing parameters input 106 is also transferred to controller 100 along input path 104 . Testing parameters input 106 comprises information regarding the specifications of the testing sequence to be implemented. In the embodiment of FIG. 1, testing parameters input 106 comprises power supply parameters 108 , motion parameters 110 , and data acquisition parameters 112 to be applied to the device under test 114 . Power supply parameters 108 are applied to power supply module 116 of controller 100 . Motion parameters 110 are applied to motion module 118 of controller 100 . Data acquisition parameters 112 are applied to data acquisition module 120 of controller 100 . The testing sequence comprises a series of one or more testing steps to be performed, in series, and/or in parallel, as appropriate, at the one or more testing locations identified in testing locations input 102 .
Therefore, the input to controller 100 essentially comprises device design file 101 , testing locations input 102 , and testing parameters input 106 . As mentioned above, device design file 101 comprises the layout file used to manufacture the wafers. This design file 101 is used for navigation purposes by the controller 100 . It provides pre-test location information and serve as a basis for user identification of preferred testing locations 102 . With this feature, users can identify testing locations 102 in a familiar format, in any desired magnification level, without necessitating scanning and evaluation of the actual wafer/device. Testing parameters input 106 provides a means for the user to provide all necessary testing specification variables for the testing sequence. And again, testing locations input 102 and testing parameters input 106 are interrelated to one another insofar as various tests specified by, testing parameters input 106 will be performed at various locations specified by testing locations input 102 .
Controller 100 is the primary interface between the user and the rest of the system. As described above, input parameters ( 108 , 110 , 112 ) are supplied by the user to controller 100 in order to specify details of the testing sequence to be implemented. Controller 100 is comprised of several modules which govern the operation of particular components of the overall so stem.
Power supply module 116 of controller 100 , translates power supply parameters 108 supplied by the user into an applied voltage train 122 that is provided to probe assembly 124 . The applied voltage train 122 may comprise a voltage and corresponding time period over which it should be applied to a specific structure on the device under test 114 , or a series of voltages and corresponding time periods to be applied to a specific structure on the device under test 114 in a specific sequence.
Motion module 118 of controller 100 translates motion parameters 110 supplied by the user into motion control information that is used throughout the entire testing sequence by many components of the system. Motion module 118 provides a probe assembly motion control sequence 126 to probe assembly 124 . In the embodiment of FIG. 1, probe assembly 124 moves in the z-direction only. This motion allows probe assembly 124 to be moved into electrical contact with the device under test 114 in order to supply the desired voltages. Typically, probe assembly 124 is lowered from a set point above the device under test 114 to a point at which electrical contact is established between probe assembly 124 and device under test 114 .
Motion module 118 also provides a device motion control sequence 128 to device holder 130 . In the preferred embodiment, device holder 130 is capable of five axes of motion that include x, y, rotation ω, and two directions of tilt, θ and φ. More specifically, x-axis motion 146 , y-axis motion 148 , ω rotation 150 , θ tilt 152 , and φ tilt 154 of the device holder 130 is provided by device motion control sequence 128 from the motion module 118 of controller 100 .
Motion module 118 also provides sensor motion control sequence 132 to sensor 134 . In the embodiment of FIG. 1, sensor 134 is capable of motion along the x, y, and z axes, though this is not limiting and other motions obvious to someone of ordinary skill can be implemented in alternative embodiments. More specifically, x-axis motion 156 , y-axis motion 158 , and z-axis motion 160 for sensor 134 is provided by sensor motion control sequence 132 from motion module 118 of controller 100 .
Alternative embodiments the invention include alternative axial and rotational/tilt motion capabilities for probe assembly 124 , device holder 130 and sensor 134 . These alternative embodiments are described in more detail later.
Data acquisition module 120 of controller 100 , translates data acquisition parameters 112 supplied by the user to sensor 134 along data acquisition pathway 136 . Subsequently, the raw test data acquired by sensor 134 is fed along the same pathway from sensor 134 to data acquisition module 120 of controller 100 . From there, the acquired raw data is sent along the data pathway 138 to data processing module 140 of the controller 100 . The raw test data is then processed, and this processed test data is then sent along the output pathway 142 to be presented as output 144 to the user.
In the preferred embodiment, sensor 134 is a single point laser based reflectometer sensor capable of making surface profile measurements as well as single point measurements. Alternative embodiments of the present invention provide alternative sensing techniques/sensors 134 that provide operational information about the microsystem device under test 114 once power is applied. Such alternative sensing techniques/sensors 134 include but are not limited to thermal imaging, thermal microscopic imaging, interferometric sensing, profilometric sensing, triangulation sensing, and CCD imaging. These alternative sensing techniques would easily assimilate into and be encompassed by the overall structure of the present invention and operational details would be the same. Of course, the nature of sensor 134 is related to the nature of the data which data acquisition module 120 can direct sensor 134 to acquire.
The operation of the controller 100 can best be described with reference to the diagram in FIG. 2, which illustrates the input and output signals of controller 100 . Controller 100 receives input 246 which comprises device design file 101 , testing locations input 102 and testing parameters input 106 as described above. Controller 100 then provides input and receives feedback from its submodules, namely power supply module 116 , motion module 118 , and data acquisition module 120 .
More specifically as earlier described, power supply module 116 provides power input to probe assembly 124 . Motion control module 118 provides motion input to probe assembly 124 for motion in the z-direction ( 248 ). Motion control module 118 also provides input to device holder 130 for 5 axis motion specifically x, y, rotation and two directions of tilt θ and φ ( 250 ). Motion control module 118 also provides motion input to the sensor 134 for motion in the x, y, and z direction ( 252 ). Data acquisition module 120 provides input and receives feedback from sensor 134 . Processed test data output 144 from data processing module 140 of controller 100 is available to the user for storage and presentation 144 .
FIG. 3 is a flowchart depicting the operation of this embodiment of the invention. At input box 354 testing locations input 102 is introduced to controller 100 . As mentioned above, testing locations input 102 comprises location identification supplied by the user of structures or points to be tested in the testing sequence. The location identification takes place in a suitable representation of the device under test 114 in design layout software. That is to say, controller 100 , in the preferred embodiment, uses the very device design file 101 that a device is designed in, and which is used to manufacture the device, to navigate the device under test 114 for testing purposes. This allows the user detailed and exact layout parameters from which to specify exact locations for test implementation. As noted earlier, testing locations input 102 may comprise, for example, point and click cross-hair identification with a mouse or, alternatively, coordinate input, all in relation to device design file 101 .
At input box 356 testing parameters input 106 is introduced to controller 100 . As mentioned above, testing parameters input 106 comprises testing specifications such as, but not limited to, sensor type, testing sequence, power or voltage ranges or sequences, and timing sequences, in relation to testing locations identified by 102 .
At process box 358 , controller 100 implements an alignment procedure to ensure that device under test 114 is accurately aligned along the axes of motion. The alignment procedure is necessary to establish a precise relative positional relationship between the locations specified by the user (testing locations input 102 ) via device design file 101 and the actual device under test 114 relative to sensor 134 . That is, sensor 134 and device under test 114 are aligned with one another so as to calibrate properly against the locations specified in device design file 101 , prior to initiating testing. This alignment utilizes motion of device holder 130 to ensure proper axial and planar alignment of the device under test 114 . Feedback front the sensor 134 verifies alignment results and adjustments can be made to all five axes until alignment meets standards set by controller 100 .
Operation continues with process box 360 in which controller 100 , via motion module 118 of the controller 100 , initiates the motion of all components necessary to position the sensor 134 at the first point on the device under test 114 to be tested as specified by testing locations input 102 . This automated motion may comprise motion of the device under test 114 via device holder 130 , motion of probe assembly 124 and/or motion of sensor 134 . The purpose of the motion is to align sensor 134 with the specific point of device under test 114 to be tested. Once sensor 134 is properly aligned to the desired location of device under test 114 , probe assembly 124 is lowered to contact device under test 114 to provide the required power to activate device under test 114 .
In the preferred embodiment of the invention, gross motion is achieved by device holder 130 for such purposes as initial alignment and motion between test points. Subsequent precise motion is achieved by sensor 134 , for such purposes as motion within a testing sequence. According to this embodiment, device holder 130 is capable of a large range of axial motion with less accuracy, and sensor 134 is capable of a much shorter range of axial motion but with great accuracy. Alternative embodiments for this motion will be obvious to someone of ordinary skill, and are considered within the scope of this disclosure and its associated claims.
Operation continues with process box 362 , in which controller 100 initiates the calibration of sensor 134 . The specifics of the calibration routine will vary dependent upon the specific type of sensor 134 being used. However, calibration 362 comprises a combination of input from motion module 118 and data acquisition module 120 of controller 100 . Typically, the calibration routine will test the operation of the sensor 134 to ensure that it is in a proper operating range and produces accurate and expected results.
Operation continues with process box 364 , in which controller 100 initiates the acquisition of the data specified by the user in testing parameters input 106 . This operation may employ one or more of data acquisition module 120 , power supply module 116 and motion module 118 of controller 100 . The specified test is implemented by sensor 134 and results sent to data acquisition module 120 of controller 100 . At the end of the acquisition of the desired raw test data, probe assembly 124 is typically raised to cease power to device under test 114 . This allows for ease of motion to the next desired testing point or replacement of the device under test 114 . This cessation of power prior to movement is particularly required for wafer level testing, since each structure has an independent set of pads from which it draws power.
Operation continues with decision box 366 in which controller 100 is queried internally based on testing location input 102 whether there is another point to be tested. If there is another point to be tested, operation loops back to just above process box 360 and continues again from there. This loop continues until all points specified by testing locations input 102 have been tested. Once the internal query is negative, the operation continues with process box 368 in which all raw test data is transferred from the data acquisition module 120 to data processing module 140 of controller 100 .
Once the raw test data is processed in data processing module 140 , operation completes with output box 370 in which the processed test data is presented 144 by controller 100 to the user 144 for additional manipulation or storage.
A first alternative embodiment of the invention is presented in FIG. 4 in which the testing components such as the device under test 114 , probe assembly 124 , device holder 130 , and sensor 134 are enclosed within a vacuum chamber 466 to allow for specialized testing sequences requiring vacuum conditions. Aside from this creation of the vacuum conditions, the system operates exactly as described above. The vacuum conditions are specified by the user among testing parameters input 106 , transferred as vacuum control parameters 470 to vacuum control module 468 and implemented by the controller 100 along pathway 472 . Alternatively, the vacuum specifications can be manually implemented by the user. Vacuum system control parameters that must be monitored for testing under vacuum conditions include but are not limited to a vacuum pressure sensor within a vacuum vessel, a vacuum pump, venting valves for vacuum elimination, and bleed valves for vacuum pressure control and regulation. The primary purposes for testing microsystems components in a vacuum environment is to mimic actual operating conditions or to provide a testing environment in which the Microsystems devices are not subjected to effects of atmospheric pressure during operation.
Another significant alternative embodiment to the present invention is a simplified system in which there is no need for a device design file 101 or testing location information 102 along input train 104 . The only input to the system comprises testing parameters 106 along input path 104 . The testing parameters 106 comprise power supply parameters 108 , motion parameters 110 , and data acquisition parameters 112 . In this embodiment, the sensor 134 is essentially used to scan a designated area of the entire device under test 114 . This embodiment is useful if no device design file 101 is available to the user. With the sensor 134 being the single point reflectometer as in the preferred embodiment, the output 144 essentially comprises device identification and location information as preliminary results to be used to specify more exact testing sequences.
Further alternative embodiments include modifications to the operation of the invention as presented in the flowchart in FIG. 3 . For example, the calibration of sensor 134 in process box 362 is only required to precede the acquisition of raw test data in process box 364 , but is not required to follow any operation except the testing locations and testing parameters input ( 102 and 106 ) represented by input boxes 354 and 356 . Therefore, the calibration of the sensor 134 (process box 362 ) can occur either before, after or in between process boxes 358 and 360 . Similarly, if multiple points or structures are to be measured, the acquired raw test data can be moved to data processing module 140 before the controller 100 moves on to the next structure. That is to say, in FIG. 3, process box 368 can be moved above decision box 366 without disrupting the operational flow. Other, similar modifications may occur to someone of ordinary skill and are considered to be within the scope of this invention and its associated claims.
A further alternative embodiment involves motion module 110 and its axial control of device holder 130 , sensor 134 and probe assembly 124 . Although specific axes of motion for the preferred embodiment were detailed above, alternative axes of motion for each of the three components 130 , 134 and 124 controlled by the motion module 110 are possible. That is to say that the motion is not limited to that described in the preferred embodiment, but can be established in a number of ways that will be apparent to someone of ordinary skill.
While only certain preferred features of the invention have been illustrated and described, many modifications, changes and substitutions will occur to those skilled in the art. It is, therefore, to be understood that this disclosure and its associated claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | An improved microsystems testing and characterization system which allows the system user to identify specific structures, and thereby to initiate an automated testing sequence to be applied to that structure or a series of structures. The integrated control system that governs the present invention automates the power supply to the device under test, the precision motion control of all components, the sensor operation, data processing and data presentation. Therefore operation is autonomous once the microstructure is in place and the testing sequence is specified. The integrated testing system can be used to perform tests on an entire wafer or on a single die. | 1 |
This is a continuation-in-part of application Ser. No. 326,615 filed Mar. 21, 1989 now abandoned, and also a continuation of Ser. No. 383,298 filed July 20, 1989.
FIELD OF THE INVENTION
The present invention is directed to plastic barricades and more specifically to one with a limiting bolt for effectively positioning the barricade in unfolded freestanding position.
DESCRIPTION OF THE PRIOR ART
Plastic barricades are well known as, for example, shown in Glass U.S. Pat. No. 4,298,186. As described in that patent, one difficulty with a plastic barricade is that the plastic material of the hinges is more susceptible to breakage than the wood or metal type barricades. And such hinges have been used for the dual purpose of both allowing the frame members of the barricade to pivot from folded to an unfolded freestanding position and to limit the opening of the two frame units of the barricade to an angle, for example, 30°-50°, suitable for its intended use as a freestanding barricade. Wood and/or metal barricades, because of the nature of the material, resist breakage much more effectively for this limiting purpose. With a plastic barricade, various modifications of the hinge per se have been made, as shown in the Glass patent, to provide a limiting function. However, these techniques have not been altogether satisfactory.
In fact, when breakage has occurred, for example, in the hinge of a plastic barricade thereby allowing it to unfold to an undesired angle or be totally unfunctional, a hole has been drilled near the hinge portion and a bolt inserted to limit movement. This was unsatisfactory in that the protruding bolt prevented effective stacking and the hinge, being still broken, made the barricade not fully operable or effective. (Or at least subject to more limited life.)
OBJECTS AND SUMMARY OF INVENTION
It is therefore a general object of this invention to provide an improved plastic barricade with effective limiting means for placing the barricade in a freestanding unfolded position.
In accordance with the above object, there is provided a plastic barricade constructed from two substantially similar generally planar frame units and which are one piece, hollow, and integrally molded, the units being hinged together to pivot around a common axis of rotation. Each of the frame units has left and right edges when an outside face of the hinged barricade is directly viewed by an observer. The improvement comprises hinge means at the top of each of the frame units including near the left edge a cylindrical male boss and near the right edge a C-shaped female socket for snapping onto the male boss and freely pivoting thereon. Such hinge means normally allow the two frame units to pivot open or unfold to an angle substantially greater than a predetermined angle used when placing the barricade in a freestanding position. Means are further provided for maintaining the barricade at the predetermined angle of the unfolded freestanding position, including for each frame unit a pair of recesses in the planar surface near each one of the edges and below the hinge means. Each recess has an aperture for accepting a machine type bolt, having a head on one end and a screw thread on the other end for one frame unit, and a nut at the other end for the other frame unit. The bolt has a length less than the distance between the planar outside faces of a folded barricade.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the plastic barricade of the present invention, showing it in an unfolded freestanding position.
FIG. 2 is a partial side view of the top portion of FIG. 1.
FIG. 3 is a plan view of the front or outside face of a frame member of the barricade.
FIG. 4 is a plan view of the inside or back face of the same frame member.
FIG. 5 is a simplified cross-sectional view taken along line 5--5 of FIG. 3.
FIG. 6 is a simplified cross-sectional view taken along the line 6--6 of FIG. 3.
FIG. 7 is a side view showing FIG. 2 in a folded or closed position.
FIG. 8 is a side view partially cut away of two stacked barricades.
FIG. 9 is an elevation view of an alternative embodiment of FIG. 1.
FIG. 10 is a simplified cross-sectional view taken along the line 10--10 of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the plastic barricade of the present invention generally indicated by the numeral 10, which consists of a pair of identical generally planar frame units 11a and 11b. These units are one piece hollow integrally molded units. In general, such a frame unit is shown in the above-mentioned Glass patent. The frame units are hinged together at their top along the axis 12 which will be described in detail below. Since the units are substantially identical, this means that in the plastic molding process only a single die may be used, thus, considerably lessening costs.
Referring briefly also to FIG. 2, when the barricade is in its normal freestanding position, the two frame units are open to an angle of substantially 40°. The bolt 13 is used to limit the opening of the barricade to this position, as will be discussed in greater detail below. However, without the bolt, the left and right hinge means 16, 17 at the top of each frame member, allow the barricade to open or freely pivot to a much greater angle than the normal 40° angle; in fact, in the case of the present hinge, to substantially totally unfold to a position where both frame units 11a and 11b are in the same plane. Thus, this construction does away with any unwanted stress on the hinge member preventing it from being broken.
Referring specifically to the detailed construction of a frame unit 11a (the other unit is identical, of course), it includes a left frame leg 18 and a right frame leg 19 which begin at the feet 21 and 22 which rest on the ground terrain and terminate in the hinges 16 and 17. Cross connecting the two legs 18 and 19 are a lower bar 23, a middle panel 24, and a top panel 25. In typical practice, both the top and middle panels may have a reflective material placed on them. In addition, the middle panel 24 may include a slot 27 into which the triangular point 28 of a road-warning sign 29 may be inserted, as illustrated in phantom. Thus, the point 28 would not be visible since it is within the panel and the legend on the warning sign 29 would have to be above that triangular portion. As more clearly illustrated in the frame unit 11b, the supporting structure or ribs 31 are also configured to accept the triangular point 28 and such ribs 31 act as a seat against which the triangular point 28 rests.
Finally, as illustrated in the case of the frame unit 11a, there is a rectangular indentation 32 in the left leg 18 and a protrusion 33 in the right leg which serves as interlocking means for stacking the panels one on top of the other. Such interlock technique is disclosed in copending application Ser. No. 183,382 filed Apr. 13, 1988, entitled "Interlocking Stacking Plastic Barricades" in the name of the present inventor. To accommodate the sign 29 these rectangular interlocking 32 and 33 may have to be slightly modified so that their top ends do not interfere.
At the top portion of the barricade between the hinges 16 and 17 are support surfaces 34 and 36 which are formed integrally with the frame member and which are horizontal when the barricade is in an unfolded position and can be used for the placement of warning lights. Typically a hole is drilled along axis 12 in the boss type hinge 16 along a bolt to be inserted to retain a warning light.
FIG. 3 shows the front or outside face of frame member 11a (and for that matter, frame member 11b) in a somewhat more simplified format than FIG. 1. The support surfaces 34, 36 are more clearly shown in FIG. 4, which should also be referred to, which shows the back of the same panel 11a. The support surfaces are of course more fully developed in this view, as also illustrated in FIG. 1, since they fill in the space between the two frame members when they are unfolded. The notch 38 or spacing between support platforms 34 and 36 is for the purpose of allowing a hand hold to pick up the barricade and to prevent any pinching of the hand as the barricade collapses. The hinges 16 and 17, of course, are reversed in position since the view is opposite to that in FIG. 3. The triangular rib formation 31 is also more clearly shown. The circled indentations at 37 are for the use in the plastic molding process and for enhancing the durability of the barricade.
Details of the hinges 16 and 17 are more clearly shown in FIGS. 5 and 6, which are cross-sectional views of the hinges, as illustrated in FIG. 3. Hinge 16, which is on the left side of the frame unit as shown in FIG. 3, is a cylindrical boss type unit 18 which is molded between supports 41 and 42. In FIG. 6 the hinge 17 is merely an open C-type clamp 43. The open part of the C is of course flexible so that this female type socket can be snapped onto the male boss 40. Other equivalent cross-sections of male boss 40 can be used; for example, it can be a semicircle, etc. All that is necessary is that there be free pivoting so that no unwanted forces are applied to the relatively fragile plastic hinge.
Below hinge 16 (see FIG. 5) is a recess 46 having an aperture 47 at its end. Similarly, in the case of FIG. 6 and hinge 17, there is a recess 48 having an aperture 49. This provides a through aperture from one face of each frame member 11a (or 11b) from one side to the other. Thus, as is more clearly illustrated in FIG. 2, the limiting bolt 13 may be inserted there-through and by the use of the bolt head 51 and the nut 52 on the other end (and washers, if necessary), this machine type bolt will limit the unfolding of the barricade to its predetermined freestanding angle which is indicated in FIG. 2 as substantially 40°. At the same time the length of the bolt type fastener 13, as illustrated in FIG. 7, is shorter or less than the distance between the planar outside faces of a folded barricade indicated as the distance L in FIG. 7. When the barricade is folded, as illustrated in FIG. 7, and another barricade stacked on it, the bolt will automatically be pushed to the neutral position shown in FIG. 7. Suitable stops (not shown) can also be used if desired. For example, a Cotter pin could be inserted at the space 53. Bolt 13 can also be replaced with an equivalent fastener.
As illustrated in FIG. 1, there are, of course, because of the nature of the molding function, two locations--both recesses 46 and 48--in which the limiting bolt 13 can be placed. It is obvious that only one bolt need be placed for effective operation.
As discussed above, the interlocking of stacked barricades, as illustrated in FIG. 8 by the barricade 10 stacked on a barricade 10', is provided as shown in FIG. 1 by the rectangular indentation 32 and the protrusion 33 on the outside face of each of the frame units. Thus, when the barricade 10 is stacked on the barricade 10', the protrusion 33 nests within the indentation 32' which is on the outside face of the frame unit 11b. Thus, assuming the same lengthwise orientation of a barricade, one folded barricade may be stacked on the other with the interlocking means automatically mating and with the planar faces of the frame units abutting each other. Moreover, in view of the construction of the fastener 13 and its recesses, this is done without obstruction or interference from the fasteners.
Rather than rectangular configurations, circular configurations may also be used, as shown in FIGS. 9 and 10, where a modified frame unit 60 is shown with left and right edges 61 and 62. Near the left edge 61 are circular indentations 57 and 59, and near the right edge 62 are circular protrusions 56 and 58. (These are better shown in FIG. 10.) In any case they interlock in the same manner, as illustrated in FIG. 8, with the rectangular interlocking devices. The foregoing interlocking procedure is more fully explained in the above-mentioned co-pending application. Thus, an improved plastic barricade has been provided which, by the use of a freely pivoting hinge, minimizes breakage of the relatively fragile plastic material. This in combination with the recessed areas allows the limiting bolt to be in place without affecting the necessary stacking facility of the barricades.
Such stacking is made possible by the built-in interlocking devices. | A plastic barricade includes improved hinges which can be freely opened to an almost flat position so that no unwanted forces cause breakage of the hinges. Limiting bolts are placed in recesses on each face of the barricade so that the bolts in the normal active position will limit the opening or unfolding of the frame units of the barricade to, for example, 40°, but when closed will still present a planar surface with the bolt heads being recessed so that stacking of one barricade on the other will not be interfered with. In addition, a slot is cut in the middle panel member to allow insertion of a road warning sign and horizontal support platform for warning lights is also provided. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a method for the manufacture of a feather quilt, and more particularly to a method for manufacturing a feather quilt by dividing the interspace between the upper and lower cloth layers of a quilt enclosure into rectangular spaces arranged in regular rows and files and blowing down into the rectangular spaces of the quilt enclosure.
Conventional feather quilts have been manufactured some by uniformly distributing down in the interspace between the upper and lower cloth layers of a quilt enclosure and stitching the upper and lower cloth layers together in properly spaced longitudinal and lateral lines and others by arranging hollow cubes of fabric containing down in regular rows and files in the interspace of a quilt enclosure and sewing these cubes to the quilt enclosure. The former feather quilts are easy to manufacture but cannot be expected to acquire ample thickness. Besides, their outer sides are awkward both in appearance and to touch. The latter multi-cube quilts come in numerous kinds and shapes. Regardless of the kind and shape, these quilts are difficult to manufacture. They also suffer from a disadvantage that the down contained therein cannot be completely prevented from moving about randomly within the interspaces of the quilts.
For the purpose of facilitating the manufacture of a multi-cube quilts, there has been proposed a method which comprises inserting partitions running in spaced longitudinal and lateral lines within the interspace between the upper and lower cloth layers of a quilt enclosure thereby forming rectangular spaces in the quilt enclosure and injecting down into the individual rectangular spaces via a down injection tube successively inserted into the rectangular spaces through the openings formed in advance in their respective partitions.
One version of this method has been known from the disclosure of Japanese Patent Publication Sho 56(1981)-1094. This method produces a feather quilt by the steps of disposing a plurality of lateral partitions at proper intervals in the interspace between the upper and lower cloth layers of a quilt enclosure and, at the same time, disposing longitudinal partitions at fixed intervals in the spaces separating the adjacent lateral partitions, with the intersections of the lateral and longitudinal partitions left unsewed, and injecting down into the rectangular spaces defined by the lateral and longitudinal partitions as orderly arranged in rows and files through the unsewed intersections.
Generally, the tube used for the injection of down into the rectangular spaces is required to have an inside diameter of not less than 30 mm. Otherwise, the tube is clogged with down and prevented from efficiently filling the rectangular spaces in the quilt enclosure with down. To form openings large enough to permit insertion of a down injection tube having an outside diameter of well over 30 mm (about 100 mm in circumferential length) by keeping the intersections of the partitions unsewed, the partitions are required to have a very large inner volume. Consequently, a huge volume of down is required to fill up all the rectangular spaces. Also disadvantageously, the down filling the rectangular spaces can move freely between the adjacent rectangular spaces through the large openings during the use of the quilt. Some rectangular spaces may bulge out and others shrink down in one and the same quilt. Thus, the down which has been originally distributed evenly in all the individual rectangular spaces will gather densely at some portions and disperse thinly at other portions. Moreover, the work of sewing the longitudinal partitions and the lateral partitions on one edge to the upper layer and on the other edge to the lower layer respectively of the quilt enclosure takes much time and labor.
To overcome the disadvantages suffered by the conventional method, the present inventor has proposed in Japanese Utility Model Application Sho 56(1981)-130619 a feather quilt manufactured by arranging, in rows and files, unit bags each having the shape of a cube and incorporating a tubular opening in either or both of the longitudinal sides thereof and injecting down into the unit bags via a down injection tube similar to the tube mentioned above, successively into the tubular openings of the unit bags. In accordance with this method, the thickness of the unit bags can be fixed without reference to the diameter of the down injection tube and the quilt can be finished in a suitable thickness. This method nevertheless has a disadvantage that the work of preparing the individual unit bags consumes much time and labor.
SUMMARY OF THE INVENTION
An object of this invention is to provide a method for the manufacture of a feather quilt which permits rectangular spaces to be easily formed in regular rows and files in the interspace between the upper and lower cloth layers of a quilt enclosure, enables down to be readily injected into the rectangular spaces, prevents down from randomly moving between the adjacent rectangular spaces, and permits the quilt to be finished in a thickness fixed without reference to the diameter of a down injection tube to be used.
To accomplish the object described above according to this invention, there is provided a method for the manufacture of a feather quilt, which comprises the steps of:
sewing slender ribbonlike partition pieces along one edge portion thereof to the opposed sides of the boundaries defining rectangular areas on the inner sides of upper and lower layers of one equal size,
sewing T-shaped partition pieces each having a slender partition portion and a projecting portion protruding from the central portion of the slender partition portion, along one edge portion thereof to the other opposed sides of the aforementioned boundaries,
opposing the corresponding ribbonlike partition pieces from the upper and lower layers, sewing their remaining edge portions together, similarly opposing the corresponding T-shaped partition pieces, sewing their remaining edge portions together with the exception of the portions from which the projecting portions rise, and superposing and sewing together the extended portions of the ribbonlike partition pieces and the T-shaped portions along the intersections of the boundaries of the rectangular spaces,
sewing the opposed lateral sides of the projecting portions of the T-shaped partition pieces from the upper and lower layers thereby forming openings one each at the leading ends of the projecting portions, and
inserting a down injection tube successively into the openings in the T-shaped projecting portions, and blowing down through this tube into the rectangular spaces.
By allowing one down injection tube to be successively inserted into the openings formed in either a longitudinal direction or a lateral direction one each in the T-shaped projecting portions of the rectangular spaces arrayed in regular rows and files, the rectangular spaces are sequentially filled with down outwardly from the innermost row. The opening in each T-shaped projecting portion is closed as the mass of down filling the rectangular space expands by its own expansive force after the withdrawal of the down injection tube. Thus, the possibility that the down placed in the individual rectangular spaces will move about randomly between the adjacent rectangular spaces is completely precluded. Since the projected opening of a width commensurate with the circumference of the down injection tube is provided near the center of the lateral side of each rectangular space, the down injection tube having a diameter greater than the thickness of the finished quilt can be easily inserted into the rectangular space. The sewing of the partition pieces to the upper and lower layers and the mutual sewing of the partition pieces can be carried out relatively easily and the introduction of down into the individual rectangular spaces can also be effected with ease. Consequently, the manufacture of the feather quilt of this invention can be accomplished without requiring much time and labor. The down placed in the rectangular spaces is now suffered to move about randomly between the adjacent rectangular spaces. Thus, the present invention produces a feather quilt which withstands prolonged service.
The other objects and characteristic features of this invention will become apparent to those skilled in the art as the disclosure is made in the following description of a preferred embodiment of the invention, as illustrated in the accompanying drawings.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a plan view of a typical upper cloth layer of a quilt having partition pieces partly attached to the inner side thereof.
FIGS. 2 and 3 are explanatory diagrams illustrating one typical condition in which partition pieces from the upper and lower cloth layers are mutually sewed.
FIG. 4 is a perspective view illustrating the condition in which the aforementioned partition pieces are mutually sewed.
FIG. 5 is a cross section illustrating the condition in which the matched edges of the upper and lower cloth layers are sewed together.
FIG. 6 is an explanatory diagram illustrating the condition in which down is injected into rectangular spaces in the quilt.
FIG. 7 is a perspective view similar to the perspective view of FIG. 4, for illustrating one modification to the condition in which openings for the passage of a down injection tube are formed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The accompanying drawings are explanatory diagrams for illustrating one embodiment of the method of this invention for the manufacture of a feather quilt. In the drawings, 1 and 2 denote rectangular upper and lower cloth layers of one equal size. In the illustrated embodiment, a total of 20 rectangular spaces 3 arranged in five files and four rows between the cloth layers. FIG. 1 illustrates the inner side of the upper layer 1, which is similar to that of the lower layer 2. To the inner sides, ribbonlike partition pieces 6 are sewed by the edge portion 6a side to all the longitudinal boundaries of the longitudinally and laterally adjoining rectangular spaces and T-shaped partition pieces 7 are sewed by the edge portion 7a side to all the lateral boundaries of the aforementioned rectangular spaces, both throughout the lengths of the respective boundaries. Of course, it is permissible for the T-shaped partition pieces 7 to be sewed by the edge portion 7a side along the longitudinal boundaries 4 and the ribbonlike partition pieces 6 by the edge portion 6a side along the lateral boundaries as will be more specifically described afterward.
The upper layer 1, the lower layer 2, and the individual partition pieces 6, 7 are made of cloth. The T-shaped partition pieces 7 comprise a ribbonlike partition portion and a projecting portion 8, either formed integrally or separately cut and subsequently joined by sewing or cementing, halfway along the edge portion 7b of the ribbonlike partition portion opposite the edge portion 6a.
The construction described above is not the only one that can be used. In the illustrated embodiment, the length of the edge portion 6a of each ribbonlike partition piece 6 is slightly smaller than the length 4L of the boundary 4 and the length of the other edge portion 6b thereof is greater than the length 4L. Thus, the ribbonlike partition piece contains at each of the opposite extremities thereof an extended portion 6c having an oblique side and protruding from the boundary 4L. Similarly, the length of the edge portion 7a of each T-shaped partition piece is slightly smaller than the length 5L of the boundary 5 and the length of the other edge portion 7b containing the projecting portion 8 is greater than the length 5L. Thus, the T-shaped partition piece similarly contains at each of the opposite extremities thereof an extended portion 7c having an oblique side and protruding from the boundary 5L. The edge portions 6a, 7a of the partition pieces 6, 7, therefore, are sewed to the inner sides of the upper and lower layers along the parts 6', 7' falling slightly inside from the edges and having lengths between the opposite oblique sides thereof equalling the lengths 4L, 5L of the respective boundaries. As a result, the extended portions 6c, 7c at the opposite extremities on the sides of the other edge portions 6b, 7b overlap as mutually liberated along the intersections of the boundaries.
After the ribbonlike partition pieces 6 have been fastened along the edge portion 6a side to all the longitudinal boundaries 4 and the T-shaped partition pieces 7 along the edge portion 7a side to all the lateral boundaries 5 on the inner sides of the upper layer 1 and the lower layer 2 as described above, the corresponding ribbonlike partition pieces 6 from the upper and lower layers are mutually sewed along their other edge portions 6b and the corresponding T-shaped partition pieces 7 are mutually sewed along their edge portions 7b containing a projecting portion 8 with the exception of the portions from which the projecting portions rise, to give rise to rectangular spaces as arrayed in regular rows and files between the upper and lower layers and to openings 9 for the insertion of a down injecting tube between the projecting portions 8 of the adjacent T-shaped partition pieces fastened to the upper and lower layers.
Then, the group of extended portions 6c and the corresponding group of extended portions 7c at the opposite extremities respectively of the paired ribbonlike partition pieces and the paired T-shaped partition pieces attached to the upper and lower layers so as to define in mutually perpendicularly intersecting directions the rectangular spaces arranged in regular rows and files are superposed and then sewed along the basal lines 10 of the superposed extended portions running vertically relative to the upper and lower layers to join the ribbonlike partition pieces and the T-shaped partition pieces integrally (FIG. 4). The superposed extended portions may be cut short, when necessary, along lines slightly outside the sewed lines 10.
To permit the partition pieces 6 and the partition pieces 7 attached to the upper and lower layers to be sewed together as described above, (I) the vertical partition pieces 6 attached to the upper and lower layers so as to separate vertically the individual rectangular spaces from one another in the lowermost row and the partition pieces 7 similarly attached so as to separate horizontally the rectangular spaces in the lowermost row from those in the second row from the bottom are sewed together along the edge portions 6b and the edge portions 7b, (II) then the partition pieces 6 separating the leftmost rectangular space and the second rectangular space from the left in the second row from the bottom are sewed together along the edge portions 6b, and (III) subsequently the extended portions of each set of four partition pieces attached to the upper and lower layers so as to intersect one another perpendicularly are drawn out as orderly superposed into the second rectangular space from the left in the second row from the bottom and the superposed extended portions are sewed together along their basal line running vertically relative to the upper and lower layers to join the aforementioned partition pieces integrally. Thereafter, the partition pieces 6 separating the second and third rectangular spaces from the left in the second row from the bottom are sewed together along their edge portions 6b and the extended portions of the corresponding set of four partition pieces are drawn out as orderly superposed into the third rectangular space from the left and the superposed extended portions are sewed together along their basal line running vertically relative to the upper and lower layers. By repeating this work, the rectangular spaces are completed in the second row from the bottom. Then, the partition pieces 7 separating the rectangular spaces in the second row and those in the third row respectively from the bottom are sewed together along the edge portions 7b. Again, the partition pieces separating the first and second rectangular spaces from the left in the third row from the bottom are sewed together along their edge portions 6b and the extended portions of these partition pieces are sewed together in an orderly superposed state. In the manner described above, all the rectangular spaces are successively formed upwardly from the bottom and rightwardly from the leftmost file. Thus, the two rightmost rectangular spaces in the uppermost row are formed finally.
Of course, the rectangular spaces may be successively formed leftwardly from the rightmost file, similarly upwardly from the bottom row. Otherwise, these rectangular spaces may be formed downwardly from the uppermost row either rightwardly or leftwardly from the left or right. Alternately, they may be formed rightwardly or leftwardly from the leftmost or rightmost file and downardly or upwardly from the uppermost or lowermost row.
In this case, when the rectangular spaces are successively formed upwardly from the lowermost row and rightwardly from the leftmost file, the left edges 1L, 2L of the upper and lower layers running parallelly to the partition pieces 6 may be joined by sewing before the partition pieces are sewed together, while the right edges 1R, 2R and the upper edges 1U, 2U running parallelly to the T-shaped partition pieces will be joined by sewing after the partition pieces are sewed together so that the free ends of the upper and lower layers may be rolled up enough for the partition pieces to be sewed together with ease. Particularly, the work of joining the edges of the upper and lower layers which run parallelly to the T-shaped partition pieces and which do not face the projecting portions 8, namely the lower edges 1B, 2B in the present embodiment, throughout the entire length thereof to close the edges will be carried out after all the rectangular spaces have been filled with down, so as to facilitate the successive insertion of the down injection tube into the opening 9.
When the left edge portions of the leftmost of all the partition pieces separating the individual rows of rectangular spaces and the right edge portions of the rightmost of all the aforementioned partition pieces and the upper edge portions of the partition pieces separating the individual rectangular spaces in the uppermost row and the lower edge portions of the partition pieces separating the individual rectangular spaces in the lowermost row are severally provided with extended portions 6c, 7c, such extended portions may be nipped between the paired edges 1L and 2L, 1R and 2R, 1U and 2U, and 1B and 2B respectively and sewed thereon at the time that these edges are tucked and sewed together (FIG. 5). Consequently, possible establishment of communication between the longitudinally and laterally adjacent rectangular spaces not merely in the inner part but equally in the outer part of the finished quilt may be perfectly precluded.
After the opposed partition pieces attached to the upper and lower layers have been sewed together and all the matched edges of the upper and lower layers excepting the lower edges have been sewed up, the down injection tube 11 is slid in through the open lower edges of the upper and lower layers and inserted through the openings formed of the projecting portions of the T-shaped partition pieces until the leading end thereof thrusts into the uppermost of the rectangular pieces in the first file. After that particular rectangular space has been filled to capacity with the down fed through the tube, the down injection tube is slightly drawn back until the leading end thereof reaches the interior of the second rectangular space from the top in the first file to supply down into this rectangular space (FIG. 6).
After the rectangular spaces in the first file have been successivley filled with the down from the uppermost row downwardly by having the down injection tube drawn back stepwise by fixed intervals along the file, the rectangular spaces in the next file are similarly filled with the down from the uppermost row downwardly. This procedure is repeated until all the rectangular spaces of the quilt are filled with the down. Optionally, for delivery to the rectangular spaces in the lowermost row, the down may be manually measured and inserted instead of being forwarded through the down injection tube. Then, after these rectangular spaces have been filled with the down, the lower edges of the upper and lower layers may be sewed together. Alternatively, the lower edges of the upper and lower layers may be sewed up with the exception of the portions left open directly opposite the rectangular spaces in the lowermost row, each in a width enough to permit insertion of the down injection tube. In this case, the down injection tube is sequentially slid in via the unsewed portions and inserted through the aforementioned openings 9, and drawn back stepwise as described above to feed the down to the rectangular spaces in the files successively from the uppermost row downwardly. After the last rectangular space in the quilt has been filled with the down, the down injection tube is completely drawn out of the quilt and the unsewed portions of the lower edges of the quilt are closed by sewing.
In the present embodiment, since the vertically adjacent rectangular spaces in a given file are allowed to communicate with one another through the openings 19 formed of the projecting portions of the T-shaped partition pieces, the down injection tube can be inserted through the rectangular spaces to supply the down into the interiors thereof as described above.
The openings 9 are formed by sewing together the edge portions 7b of the T-shaped partition pieces attached to the upper and lower layers, with the exception of the projecting portions 8. In this case, the statement that the edge portions are sewed together with the exception of the T-shaped projecting portions can imply two cases, one in which the opposite lateral sides of the T-shaped projecting portions are sewed as continued at right angles to the edge portions 7b, with the leading ends only left unsewed as illustrated in FIGS. 2-4 (former case) and another in which the opposite lateral sides and the leading ends of the T-shaped projecting portions are left unsewed as illustrated in FIG. 7 (latter case). In the former case, the openings 9 are formed in a tubular shape. After a given rectangular space has been filled with the down, the opening 9 of this rectangular space flattens, bends down, and gets clogged with the down held inside the rectangular space when the down injection tube is pulled out of this opening. The opening 9 thus reduced to a crushed, clogged state perfectly prevents possible random movement of the down between the adjacent rectangular spaces. In the latter case, the openings are not formed in a tubular shape. When the down injection tube is drawn out of a given rectangular space, however, the free T-shaped projecting pieces of this rectangular space overlap and bend down and, similarly to the former case, provide prevention of the random movement of the down between the adjacent rectangular spaces. Yet, there is a possibility that the down will force its way through the lateral sides into the space embraced between the T-shaped projecting pieces. The most desirable way of forming the openings, therefore, is by joining the opposite lateral sides by sewing as in the former case. Generally, for the projecting portions 8 to fulfill their function advantageously, they are required to have a width of about 7 to 12 cm and a height of about 5 to 12 cm.
In the illustrated embodiment, the T-shaped partition pieces 7 are sewed to the upper and lower layers along the lateral boundaries of rectangular spaces. As already described, the present invention can be equally embodied by having the T-shaped partition pieces sewed along the longitudinal boundaries of rectangular spaces and the ribbonlike partition pieces 6 similarly along the lateral boundaries thereof. In this case, the finishing of the quilt may be accomplished by inserting the down injection tube through the rectangular spaces in one row until the leading end thereof reaches the farthest of such rectangular spaces, blowing the down into the farthest rectangular space through the tube until the space is filled to capacity, then drawing the tube back stepwise by fixed intervals to move the leading end of the tube from one to the next rectangular space in the row while keeping continual supply of the down to the successive rectangular spaces in the row, and repeating the reciprocating travel of the down injection tube through the rectangular spaces sequentially in all the remaining rows.
When the down injection tube is inserted through the rectangular spaces in a file or when it is inserted through the rectangular spaces in a row, the insertion should be made in the direction from the basal portion to the leading end of the T-shaped projecting portion of each of the successive rectangular spaces and never in the opposite direction, so as to ensure easy passage of the tube through the openings concealed within the rectangular spaces.
In accordance with this invention, the rectangular spaces arrayed in regular rows and files can be easily formed in the interspace between the upper and lower cloth layers of a quilt enclosure by attaching ribbonlike partition pieces to the upper and lower layers along the boundaries of such rectangular spaces running in one of the two perpendicularly intersecting directions and the T-shaped partition pieces similarly along the boundaries thereof running in the other direction and sewing the corresponding ribbonlike partition pieces and the corresponding T-shaped partition pieces together while keeping the upper and lower layers rolled up. Further, the T-shaped partition pieces serve to provide no-return type openings which permit ready insertion of the down injection tube for supply of the down to the interiors of the rectangular spaces and which prevent the down already placed in the rectangular spaces from randomly moving about between adjacent rectangular spaces. | A feather quilt comprising upper and lower cloth layers, a multiplicity of rectangular spaces arrayed in regular rows and files in the interspace between the upper and the lower layer, and down placed to fill up the rectangular spaces is manufactured by sewing ribbon-like partition pieces to the inner sides of the upper and lower layers along the individual boundaries of the rectangular spaces running in the longitudinal (or lateral) direction and T-shaped partition pieces to the aforementioned inner sides along the individual boundaries of the rectangular spaces running in the lateral (or longitudinal) direction, sewing together the corresponding ribbonlike partition pieces fastened to the upper and lower layers, similarly sewing the T-shaped partition pieces together with the exception of the openings formed of the projecting portions thereof, and sequentially filling with down the rectangular spaces formed between the upper and lower layers by the use of a down injection tube inserted through the openings into the interiors of the successive rectangular spaces. By this method, a feather quilt of any desired thickness can be easily and efficiently manufactured without reference to the diameter of the down injection tube used for the transfer of the down. | 3 |
FIELD OF THE INVENTION
The present invention relates to wireless communication, and in particular to wireless messaging.
BACKGROUND OF THE INVENTION
Mobile communication devices, such as cell phones, personal digital assistants (PDAs) and laptop computers, are very widespread, and have become an essential part of modern life. Such devices generally communicate via voice or instant messages. Most instant messages use the Short Message Service (SMS) protocol for sending text messages, but other messages, such as Multimedia Messaging Service (MMS) messages, are also very much in use. According to http://en.wikipedia.org/wiki/Short message service, currently 2.4 billion active users around the world, which is roughly 74% of all mobile phone subscribers, send and receive text messages on their phones.
The SMS Point-to-Point protocol (SMS-PP) is defined in GSM Recommendation 3.40*. Messages are sent to a Short Message Service Center (SMSC), which provides store-and-forward functionality, for transmission to recipients. SMSC supports mobile-terminated (MT) functionality, for messages sent to a mobile handset, and supports mobile-originating (MO) functionality, for messages sent from a mobile handset.
Transmission of messages from the SMSC to a recipient mobile handset is in conformance with the Mobile Application Part (MAP) of the SS7 protocol. In particular, messages are sent using the MAP ForwardSM operations, which limits the length of messages to 140 octets; i.e., 1,120 bits. Routing data and other metadata is added to the message, beyond the 1,120 bit limit.
SMS messaging supports two modes; namely, text and data. For text mode, the message uses the default GSM 7-bit alphabet for regular text messages, supporting 70 characters; and uses 16-bit UCS-2 character encoding for languages such as Arabic, Chinese, Korean, Japanese, and for Cyrillic alphabet languages such as Russian, supporting 160 characters. For data mode, the message uses 8-bit characters and supports 140 characters. Data mode supports inter alia the following services.
WAP Push, which is an encoded message that includes a link to a WAP or WWW address. WAP Push enables WAP content to be pushed to a mobile handset with minimal user intervention. A Push Proxy Gateway (PPG) processes WAP Pushes and delivers them over an IP or SMS bearer. OTA Settings, which relate to setup of new services, such as GPRS, MMS and Instant Messaging, for a subscriber of a mobile phone network. MMS Notification, which indicates when a new MMS messages has been received on the Multimedia Messaging Service Center (MMSC). Depending on the phone settings, the message may be automatically downloaded from the MMSC, if a GPRS or UMTS connection is available. Push E-mail, for receiving e-mail messages on a mobile handset.
A drawback with SMS messaging is the relatively high cost. According to a recent study the University of Leicester, http://www.spacemart.com/reports/SMS Texting Costs Are Out of This World 999.html, sending text messages by mobile phones is far more expensive than downloading data from the Hubble Space Telescope. Operators charge subscribers per SMS text message, or offer SMS plans, such as unlimited SMS texting for a fixed monthly rate. For some plans, pricing is different for messages sent within a network or within a predefined group, than for messages outside of the network or group.
Costs for instant messaging generally comprise a significant portion of subscribers' monthly fees. The expense is often excessive, since many subscribers perceive sending of text messages as being inexpensive, and much cheaper than phone calls.
A factor that contributes to excessive messaging expenses is the distribution of messages to a group of friends. Often a subscriber broadcasts messages to his friends notifying them of events, or about his status. E.g., if the friends wish to go to a movie together, the subscriber may send a message notifying them of the time and place. Messaging applications, such as 3jam developed by 3jam, Inc, of San Francisco, Calif., and Send'm developed by SEND-M, Ltd, of Or Yehuda, Israel, enable users to send a message to a group of friends. Generally, each member of the group knows which group members are on the mailing list, and may reply to some or all of the group members.
A disadvantage of sending of group messages using conventional technology is that the subscriber who initiates the message must bear the entire cost of the communication. Another disadvantage of sending of group messages using conventional technology is that the initiator of the message does not know whether the recipients actually received the message.
SUMMARY OF THE DESCRIPTION
Aspects of the present invention overcome these disadvantages described above, by providing methods and systems (i) for sharing the expenses of distributing messages among members of a group, using mobile communicators, and (ii) for ensuring that the initiator of the message receives a confirmation if the message was successfully distributed to all members of the group. As used herein, the term mobile communicator refers to an electronic device that sends and receives data over a wireless communication network. A mobile communicator includes inter alia a cell phone, a portable data assistant (PDA), a laptop computer, and other such devices that include modems. As used herein, the term message refers to data that is transmitted from a first person to a second person. A message includes inter alia a text message, a multimedia message, an e-mail message and a voice message. A message may be informational, such as notification of an event, or may additionally solicit a response or a vote from each recipient.
In one embodiment of the present invention, a member of a group is able to distribute a message among other members of the group by specifying the group as being the recipient of the message. The message is then automatically circulated among the members of a group according to a routing order. The message is received and forwarded by one member to another, until the message has completed a traversal through the entire group.
Embodiments of the present invention address the creation of groups, and the determination of one or more routing orders for circulating messages among the group.
Embodiments of the present invention further address overcoming problems when one or more of the members of the group are inaccessible.
There is thus provided in accordance with an embodiment of the present invention a method for circulating a message to a group of people, including sending a circulated message by a 1 st mobile communicator, and sequentially receiving the circulated message by an n th mobile communicator and sending the circulated message to an (n+1) st mobile communicator, n=2, 3, . . . , N−1, wherein each one of the N mobile communicators has a distinct phone number.
There is additionally provided in accordance with an embodiment of the present invention a communication system, including a plurality of N mobile communicators, each having a distinct phone number, and circuitry in each of the plurality of mobile communicators, (i) for sending a circulated message by the 1 st mobile communicator, and (ii) for sequentially receiving the circulated message by the n th mobile communicator and sending the circulated message to the (n+1) st mobile communicator, n=2, 3, . . . , N−1.
There is further provided in accordance with an embodiment of the present invention a method of communication, including receiving a circulated message, by a destination mobile communicator, from a previous destination mobile communicator, and sending the circulated message to a next destination mobile communicator, where the previous destination mobile communicator, the destination mobile communicator and the next destination mobile communicator are successive members of an ordered list of mobile communicators, if the destination mobile communicator is not the last member of the ordered list.
There is yet further provided in accordance with an embodiment of the present invention a destination mobile communicator, including a modem for sending and receiving messages, a memory for storing a group of identifiers of mobile communicators, and an ordered list thereof, and modem controller circuitry communicatively coupled with the modem and with the memory, for controlling the modem (i) to receive a circulated message from a previous destination mobile communicator, and (ii) to send the circulated message to a next destination mobile communicator, where the previous destination mobile communicator, the destination mobile communicator and the next destination mobile communicator are successive members of the ordered list of mobile communicators stored in the memory, if the destination mobile communicator is not the last member of the ordered list.
There is moreover provided in accordance with an embodiment of the present invention a method of billing subscribers to a communication service, including identifying a message that was distributed to members of a pre-defined group of subscribers, further identifying all transmissions of the distributed message from one member of the group to another member of the group, as the distributed message traversed all members of the group, and allocating the total cost of the identified transmissions equally among the members of the group.
There is additionally provided in accordance with an embodiment of the present invention a billing system for subscribers to a communication service, including an activity monitor (i) for identifying a message that was distributed to members of a pre-defined group of subscribers, and (ii) for further identifying all transmissions of the distributed message from one member of the group to another member of the group, as the distributed message traversed all members of the group; and a billing manager, coupled with the activity monitor, for allocating the total cost of the identified transmissions equally among the members of the group.
There is further provided in accordance with an embodiment of the present invention a method for circulating a message to a group of people, including sending a circulated message and a distribution list including identifiers for a plurality of mobile communicators, by a first mobile communicator, and sequentially receiving the circulated message and a distribution list, by a next mobile communicator, and, if the received distribution list is non-empty, then (i) selecting one of the mobile communicators identified in the distribution list, (ii) modifying the distribution list by removing the identifier of the selected mobile communicator therefrom, and (iii) sending the circulated message and the modified distribution list to the selected mobile communicator.
There is yet further provided in accordance with an embodiment of the present invention a communication system, including a plurality of mobile communicators, and circuitry in each of the plurality of mobile communicators, (i) for sending a circulated message and a distribution list comprising identifiers for a plurality of mobile communicators, and (ii) for successively receiving the circulated message and a distribution list, by a next mobile communicator, and, if the received distribution list is non-empty, then (ii.a) selecting one of the mobile communicators identified in the distribution list, (ii.b) modifying the distribution list by removing the identifier of the selected mobile communicator therefrom, and (ii.c) sending the circulated message and the modified distribution list to the selected mobile communicator.
There is moreover provided in accordance with an embodiment of the present invention a method for creating a group of mobile communicators, including sending an invitation from an originator mobile communicator to a plurality of other mobile communicators, receiving responses from the plurality of other mobile communicators, the responses indicating acceptance or non-acceptance of the invitation, creating group information including (a) identifiers of group members, the group members including the mobile communicators from which responses indicating acceptance of the invitation were received, and (b) an ordered list of the group members for use in circulating messages among the group members, and sending the group information to the group members.
There is additionally provided in accordance with an embodiment of the present invention a communication system, including a plurality of mobile communicators, and circuitry in each of the plurality of mobile communicators, (i) for sending an invitation from such mobile communicator to the other mobile communicators, (ii) for receiving responses from the other mobile communicators, the responses indicating acceptance or non-acceptance of the invitation, (iii) for creating group information including (a) identifiers of group members, the group members including the mobile communicators from which responses indicating acceptance of the invitation were received, and (b) an ordered list of the group members for use in circulating messages among the group members, and (iv) for sending the group information to the group members.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood and appreciated from the following detailed description, taken in conjunction with the drawings in which:
FIG. 1 is a simplified diagram of a system for circulating a message among members of a group of mobile communicators, in accordance with an embodiment of the present invention;
FIG. 2 is a simplified flowchart of a method for creating a group of mobile communicators for message circulation, in accordance with an embodiment of the present invention;
FIG. 3A is a simplified flowchart of a method for circulating a message among a group of mobile communicators according to a pre-determined order, in accordance with an embodiment of the present invention;
FIG. 3B is a simplified flowchart of a method for circulating a message among a group of mobile communicators according to an ad-hoc order, in accordance with an embodiment of the present invention;
FIG. 4 is a prior art diagram illustrating operation of SMS messaging;
FIG. 5 is a simplified flowchart of a method for a mobile communicator to send an SMS message to a recipient, if message delivery problems arise, in accordance with an embodiment of the present invention;
FIG. 6 is a simplified diagram of a wireless communicator that listens for group messages, in accordance with an embodiment of the present invention; and
FIG. 7 is a simplified flowchart of a method for allocating the cost of distributing a message to members of a group, among the members, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
Aspects of the present invention relate to distributing messages to members of a group using wireless communicators. In one embodiment, a member of a group distributes a message among the other members of the group by designating the group as being the recipient of the message, when sending the message. The message is then routed in a specific routing order, from one member of the group to the next, until the message has circulated through the entire group.
In terms of billing, since each member is billed for sending the message to the next member, the cost of distributing the message to the group is automatically shared among the members of the group.
In accordance with an embodiment of the present invention, each of the members' mobile communicators has circuitry therein that is programmed to receive a message being circulated and automatically send it to a next mobile communicator.
Reference is now made to FIG. 1 , which is a simplified diagram of a system for circulating a message among members of a group of mobile communicators, in accordance with an embodiment of the present invention. Shown in FIG. 1 is a group of four mobile communicators, corresponding to users Andy, Bill, Charlie and David, and denoted respectively 100 a , 100 b , 100 c and 100 d . Also shown in FIG. 1 is a simplified block diagram of a general mobile communicator 100 , which includes a modem 110 , a controller 120 and a memory 130 . Controller 120 includes circuitry for controlling modem 110 to send and receive messages. Memory 130 stores data including inter alia identifiers of group members, such as Andy, Bill, Charlie and David, and a representation of an ordered list of the members, such as Andy→Bill→Charlie→David.
When Andy's mobile communicator sends a message for circulation among the group, the message is automatically routed from Andy→Bill→Charlie→David. Each mobile communicator has sufficient information to identify the recipient to whom it must forward the message that it receives. Upon receipt of the message, David's mobile communicator, being the last member in the routing order, sends a status report to Andy's mobile communicator confirming receipt of the circulated message. Upon receipt of the status report, Andy knows that his message was successfully distributed to all members of the group.
It will be appreciated by those skilled in the art that the cost of circulating the message among the group is automatically shared among the members of the group. Andy is billed for the message sent from Andy to Bill. Bill is billed for the message sent from Bill to Charlie. Charlie is billed for the message sent from Charlie to David. David is billed for the status report sent from David to Andy. In distinction, had Andy sent the message to each of the members of the group using conventional technology, then Andy would be billed for sending three messages, and Bill, Charlie and David would not be billed at all.
Reference is now made to FIG. 2 , which is a simplified flowchart of a method for creating a group of mobile communicators for message circulation, in accordance with an embodiment of the present invention. At step 1010 a subscriber, referred to as the owner of the group, sends an invitation to a plurality of recipients to join a group. The invitation is sent from the owner's mobile communicator to each of the recipients' mobile communicators. At step 1020 the recipients receive the invitation to join the group.
At step 1030 each recipient sends a response to the owner indicating acceptance or non-acceptance of the invitation. The response is sent from the recipients' mobile communicators to the owner's mobile communicator. At step 1040 the owner modifies the group according to the recipient responses, thereby defining the members of the group; namely, those recipients who accepted the invitation. The recipients who opted out are not included as members of the group.
At step 1050 the owner designates an ordered list of the members of the group. The list determines an ordering, member #1, member #2, . . . , member #N, where N denotes the number of members of the group. In terms of its data representation, the ordered list of members may be represented as a sequence of phone numbers, or as a sequence of pointers to phone numbers, or as such other data structure for representing an ordered list of mobile communicators.
Often it is convenient to endow an ordered list with a circular structure, whereby the last member is connected back to the first member; i.e., 1→2→ . . . →N→1. Any member of the group may then use the circular list, starting from himself, to circulate a message among the other members of the group according to the order of the list. E.g., member #4 may initiate a message to be circulated among the other group members, according to the order 4→5→ . . . →N→1→2→3. Each member's mobile communicator automatically receives the message and sends it to the next member in the list, with member #N sending the message to member #1.
At step 1060 the owner stores the group information, including the members of the group and their phone numbers, and the ordering of the members, in his mobile communicator. At step 1070 the owner sends the group information to the members of the group. At step 1080 the members of the group receive the group information and store the information in their mobile communicators.
At this stage, each mobile communicator has stored therein information identifying the members of the group and the ordering of the members. Thereafter, the owner of the group may edit the group by adding or deleting members, and by changing the ordering of the members. Generally, when the owner edits the group a notification describing the modified group is sent to the members of the group, so that their mobile communicators are synchronized.
By accepting the invitation to join the group at step 1030 , each member agrees to share the costs for circulating messages among the group. A member of the group may subsequently decide to remove himself from the group, in which case he sends a message to the owner of the group requesting that he be removed.
In alternative embodiments of the present invention, creation of a group is performed ad-hoc “on-the-fly” when the need to circulate a message among the group arises. In such case, when a member of the ad-hoc group receives the message, he may “accept” the message and agree to forward it to the next member of the group. If the member does not accept, then the initiator receives a notification, in which case he may re-send the message to a modified group, or send the message to the next member following the recipient who opted out, thereby bearing the cost that would have been borne by the recipient who opted out.
Reference is now made to FIG. 3A , which is a simplified flowchart of a method for circulating a message among a group of mobile communicators according to a pre-determined order, in accordance with an embodiment of the present invention. At step 1110 a member of the group, referred to as the message initiator, sends a message to be circulated among a group of members, such as the group created by the method of FIG. 2 . The initiator does so by designating the group as being the recipient of the message. The group of members has a pre-determined ordering associated therewith, such as the ordering determined at step 1050 . At step 1120 the initiator's mobile communicator automatically identifies the first mobile communicator from the ordered list of members of the group, based on the group information stored in the initiator's mobile communicator, and sends the message to the first mobile communicator.
At step 1130 the current mobile communicator receiving the circulated message consults the group information stored in the current mobile communicator, and determines whether the current mobile communicator is the last member in the ordering of the group members. If not, then the current mobile communicator identifies the next member in the ordering of the members, and at step 1140 sends the circulated message to the next member. The method then returns to step 1130 . Otherwise, if the current mobile communicator is the last member of the group, then at step 1150 the current mobile communicator sends a status report to the initiator, indicating that it successfully received the circulated message. Until the initiator receives the status report, he cannot confirm that the message was successfully circulated to all members of the group.
It will be appreciated by those skilled in the art that because each member sends the circulated message to another member, the cost of circulating the message among the group is automatically shared among the members. Each member is billed for the message that he sends to one recipient.
Reference is now made to FIG. 3B , which is a simplified flowchart of a method for circulating a message among a group of mobile communicators according to an ad-hoc order, in accordance with an embodiment of the present invention. In distinction from the method of FIG. 3A which uses a pre-determined order, the method of FIG. 3B uses an ad-hoc order specified by the message initiator. At step 1210 the initiator of the message species an ordered list of members of a group. The initiator of the message is appended at the end of the ordered list, so as to be the last member of the list. E.g., if Andy is the initiator of the list then the list may indicate Bill→Charlie→David→Andy. Alternatively, members of the group may have personal ordered lists of the group members stored in their mobile communicators. For example, as described hereinabove, each member may use a circular list of the group members, starting immediately after himself, as his personal ordered list. Thus for the circular list Andy→Bill→Charlie→David→Andy, Bill's personal ordered list is Charlie→David→Andy→Bill, and Charlie's personal ordered list is David→Andy→Bill→Charlie. In such case step 1210 is obviated and the initiator's personal list is used instead of an ad-hoc list.
At step 1220 the initiator sends a message to the group, by designating the group as the recipient of the message. The initiator's mobile communicator automatically embeds the ordered list within the message. As indicated hereinabove, the ordered list may be represented as a sequence of phone numbers, or as a sequence of pointers to phone numbers, or as such other data structure for representing an ordered list of mobile communicators.
At step 1230 the initiator's mobile communicator automatically sends the list to the first mobile communicator in the list, i.e. Bill's communicator in the example above where Andy is the initiator. At step 1240 the current mobile communicator receiving the message extracts the ordered list in the message to determine if the current mobile communicator is the next-to-last member of the list. If not, the current mobile communicator consults the list to determine the next member, and at step 1250 the current mobile communicator sends the message to the next member. The method then returns to step 1240 . Otherwise, if the current mobile communicator is the next-to-last member of the list, then at step 1250 the current mobile communicator sends a status report to the last member of the list; i.e., to the initiator of the list, indicating successful receipt of the message. As above, until the initiator receives the status report, he cannot confirm that the message was successfully circulated to all members of the group.
In an alternative embodiment of the present invention, at step 1250 the current mobile communicator shortens the embedded list by removing himself from the beginning of the list. In this way, less and less data is transmitted as the message circulation advances from member to member. E.g., referring to the example above, after Bill receives the message, his mobile communicator truncates the ordered list to Charlie→David→Andy prior to sending the message to Charlie; and after Charlie receives the message, his mobile communicator truncates the ordered list to David→Andy prior to sending the message to David.
It will be appreciated by those skilled in the art that the message circulated by the methods of FIGS. 3A and 3B may be an informational message, or additionally a message requesting a response or vote from the members of the group. Each member receiving the message may respond or vote according to criteria set by the initiator. E.g., the message may ask whether the member wishes to go to a movie at 9:00 PM, and the initiator may enable a “Yes” and a “No” reply. Each recipient is then presented with the “Yes” and “No” replies. The replies themselves may be sent directly to the initiator. In such case, each recipient sends two messages; namely, the circulated message to the next recipient in the ordered list, and the reply to the initiator. Alternatively, each recipient's reply may be concatenated to the circulated message. In such case, the circulated message grows in length as it circulates through the group members.
One of the challenges with message circulation by the methods of FIGS. 3A and 3B is how to deal with situations where the circulated message does not reach one of the group members. E.g., the member's mobile communicator may be turned off, or the mobile communicator's SMS memory limit may be exceeded.
In this regard, reference is made to FIG. 4 , which is a prior art diagram illustrating operation of SMS messaging. Shown in FIG. 4 is an originator mobile phone 210 , a recipient mobile phone 220 and a short messaging service center 230 . Originator mobile phone 210 sends an SMS message to recipient mobile phone 220 . The SMS message is transmitted to SMS center 230 , for further transmission to recipient mobile phone 220 . If recipient mobile phone 220 is inaccessible, the SMS message is temporarily stored in SMS center 230 . SMS center 230 sends the message later when recipient mobile phone 220 becomes accessible. A time period, referred to as a validity period, may be specified, after which time the SMS message is deleted from SMS center 230 . As such, if recipient mobile phone 220 does not become accessible within the validity period, then the SMS message will not be sent when recipient mobile phone 220 subsequently does become accessible.
A flag may be set in the SMS message to notify SMS center 230 to provide a status report about delivery of the SMS message. The status report is sent to originator mobile phone 210 in the form of an SMS message. When the SMS message sent by originator mobile phone 210 reaches SMS center 230 , SMS center 230 sends a submission report back to originator mobile phone 210 , as indicated in FIG. 4 . The submission report indicates either successful receipt of the SMS message, or failure. Failure may be due to an incorrect SMS message format, or due to SMS center 230 being busy.
If originator mobile phone 210 does not receive the submission report after a designated period of time, it concludes that the submission report was lost, and originator mobile phone 210 may re-send the SMS message. A flag is set in the re-sent SMS message to indicate that the SMS message was sent previously. If the previous submission report was successful, SMS center 230 ignores the re-sent SMS message and sends a submission report to original mobile phone 210 , thus avoiding sending of the same SMS message multiple times to recipient mobile phone 220 .
When the SMS reaches recipient mobile phone 220 , recipient mobile phone 220 sends a delivery report to SMS center 230 , as indicated in FIG. 4 . The delivery report indicates either successful receipt of the SMS message, or failure. Failure may be due to an unsupported message format, or insufficient free storage space available in recipient mobile phone 220 . In turn, SMS center 230 sends a status report to originator mobile phone 210 , after receiving the delivery report from recipient mobile phone 220 , as indicated in FIG. 4 . If SMS center 230 does not receive the delivery report after a designated period of time, it concludes that the delivery report was lost, and re-sends the SMS message to recipient mobile phone 220 .
In accordance with an embodiment of the present invention, the owner of a group may set a validity period for the SMS message distributed to the group. After the validity period, the SMS message will not be further distributed.
Further in accordance with an embodiment of the present invention, if the sender of a message to be distributed among group members receives a negative submission report, then the message is re-sent after a pre-defined time, such as 5 minutes. If sending of the re-sent message fails, then the message may be re-sent again, up to a designated maximum number of tries. If the sending of the re-sent message fails for all of the tries, then an error message is sent to the group owner.
If the sender of the message receives a negative status report, then the message is sent to the next recipient in the list of members. E.g., for the list Andy→Bill→Charlie→David, if Charlie's mobile communicator is inaccessible, then Bill's mobile communicator receives a negative status report, and the message is then automatically sent from Bill's mobile communicator to David, with appropriate changes as necessary.
Reference is now made to FIG. 5 , which is a simplified flowchart of a method for a mobile communicator to send an SMS message to a recipient, if message delivery problems arise, in accordance with an embodiment of the present invention. At step 1305 , the mobile communicator identifies a next member in the list of members, as a recipient of the SMS message. At step 1310 a counter, K, is initialized to K=1. The counter, K, counts the number of tries to send the SMS message to the recipient identified at step 1305 . At step 1315 the mobile communicator tries to send the SMS message to the recipient. At step 1320 a determination is made whether or not a positive submission report is received. If not, then at step 1325 the method waits for a pre-defined amount of time, such as 5 minutes, and the counter, K, is advanced by one. At step 1330 a determination is made whether K has reached the limit on the number of tries. If not, then processing returns to step 1315 where the mobile communicator tries again to send the SMS message to the recipient. If it is determined at step 1330 that K has reached the limit on the number of tries, then the method fails at step 1335 and a notification of failure is sent to the owner of the group.
Referring back to step 1320 , if a positive submission report is received, then processing advances to step 1340 , where a determination is made whether or not a positive status report is received. If so, then the method ends successfully at step 1345 . If not, a determination is made at step 1350 if the recipients identified at step 1305 have exhausted the alternatives for recipients in the list of members. Generally, the alternatives for recipients are those recipients whose positions in the list are after the position of the mobile communicator performing the method of FIG. 5 . If the alternative recipients have been exhausted, then the method fails at step 1335 and a notification of failure is sent to the owner of the group. Otherwise, processing returns to step 1305 where a next recipient is identified.
Implementation Details
Reference is now made to FIG. 6 , which is a simplified diagram of a wireless communicator that listens for group messages, in accordance with an embodiment of the present invention. Shown in FIG. 6 are a Short Messaging Service Center (SMSC) 310 , a Push Proxy Gateway (PPG) 320 , a WAP Push server 330 , a Multimedia Message Service Center (MMSC) 340 , a Push E-mail server 350 , and an OTA server 360 . Messages sent via MAP (Mobile Application Part of the SS7 Protocol) operations generally include a designated port within their metadata. As such, in an implementation of the present invention, mobile communicator 100 listens to the designated port.
In reading the above description, persons skilled in the art will appreciate that there are many apparent variations that can be applied to the methods and systems described. One such variation is the algorithm used for circulating a message so that it traverses an entire group. The algorithm illustrated in FIGS. 1 , 2 , 3 A and 3 B corresponds to an ordered list, but other algorithms may be used instead. For example, with large groups it is of advantage to use a tree traversal such as a binary tree traversal, wherein each mobile communicator that receives the message forwards it to two members of the group. When the bottom nodes of the tree receive the message, they send a confirmation back to the parent, which then travels upwards through the tree back to the initiator of the message. With a large group of, say, 1,000 members, the binary tree traversal requires 10 levels of message forwarding down through the tree, and 10 levels of confirmation forwarding back up through the tree. In distinction, an ordered list requires 1,000 sequential message transmissions. Similarly, other graph traversal algorithms may also be used with the present invention.
Another such variation to the methods and systems described herein is to send a message from the initiator of the message directly to all other members of the group, and to enable the operator of the messaging service to allocate the cost equally among the members of the group, either on a per message basis, or an a monthly subscription plan. In accordance with an embodiment of the present invention, the operator uses an activity monitor 410 ( FIG. 6 ) to identify a message distributed to members of a group, and to further identify all transmissions of the distributed message from one member of the group to another. The operator further uses a billing manager 420 to allocate the cost of all of the identified transmissions equally among the members of the group.
Reference is now made to FIG. 7 , which is a simplified flowchart of a method for allocating the cost of distributing a message to members of a group, among the members, in accordance with an embodiment of the present invention. The method of FIG. 7 is performed by an operator of the messaging service used by mobile communicators. At step 1410 a monitor, such as activity monitor 410 , identifies a message that was distributed among a pre-determined group of subscribers. At step 1420 the monitor identifies all transmissions of the distributed message from one member of the group to another member, as the distributed message traversed all members of the group. At step 1430 a billing system, such as billing manager 420 , allocates the cost of all of the identified transmissions among members of the group.
In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made to the specific exemplary embodiments without departing from the broader spirit and scope of the invention as set forth in the appended claims. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | A method for circulating a message to a group of people, including sending a circulated message by a 1 st mobile communicator, and sequentially receiving the circulated message by an n th mobile communicator and sending the circulated message to an (n+1) st mobile communicator, n=2, 3, . . . , N−1, wherein each one of the N mobile communicators has a distinct phone number. A system is also described and claimed. | 7 |
FIELD OF THE INVENTION
The invention relates to a device for the production of a spun thread from a fibre sliver, encompassing a fibre conveying channel with a fibre guide surface for the guidance of the fibres of the fibre sliver into the inlet aperture mouth of a yarn guidance channel, and further comprises a fluid device for the production of an eddy current around the inlet aperture mouth of the yarn guidance channel.
BACKGROUND
Such a device is known from DE 44 31 761 C2 (U.S. Pat. No. 5,528,895) and is shown in FIGS. 1 and 1 a . In this, fibres are guided through a fibre bundle passage 13 on a twisted fibre guidance surface, which exhibits a “rear” edge 4 b about a “front” edge 4 c . The fibres are then guided around what is referred to as a needle 5 into a yarn passage 7 of what is referred to as a spindle 6 , whereby the rear part of the fibres are rotated by means of an eddy current generated by nozzles 3 about the front part of the fibres, already located in the yarn passage, with a yarn being formed as a result. Once this has been done, spinning takes place, as is described later in connection with the invention.
The element referred to as the needle, and its tip about which the fibres are guided, is located close to or in the inlet aperture mouth 6 c of the yarn passage 7 and serves as what is referred to as a false yarn core, in order as far as possible to prevent or to reduce the possibility that, due to the fibres in the fibre bundle passage, an impermissibly high false twist of the intertwined fibres occurs, which would at least interfere with the formation of the yarn if not even preventing it altogether.
FIG. 1 b shows this aforementioned prior art encumbered with disadvantages (DE 41 31 059 C2, U.S. Pat. No. 5,211,001), in that, as is known from DE 44 31 761, FIG. 5 , the fibres are not guided consistently about the needle as shown in FIG. 1 a , but are guided on both sides of this needle against the inlet aperture mouth of the yarn passage, which apparently interferes with the binding of the fibres and apparently can lead to a reduction of the strength of the spun yarn.
FIG. 1 c shows a further development of FIG. 1 , or 1 a respectively, in that the fibre guidance surface 4 b , as can be seen, is designed in a helical shape, and the fibres are accordingly likewise guided in helical form in their course from the clamping gap X as far as the end e 5 of the helical surface, and are then wound, still in helical form, about a fibre guidance pin, similar to the fibre guidance pin 5 of FIG. 1 , before the fibres are acquired by the rotating air flow and twisted to form a yarn Y. In this situation, it can be seen that the rear ends of the fibres f″ are bent about the mouth part of the spindle 6 , and in this context are taken up by the rotating air flow and wound around the front ends, which are already located in the center of the fibre run, in order to form the yarn as a result.
FIG. 1 c corresponds to FIG. 6 from DE 19603291 A 1 (U.S. Pat. No. 5,647,197), whereby the identification references of the spindle 6 , the yarn passage 7 , and the venting cavity 8 have been adopted from FIG. 1 , while the element e 2 , which has a similar function to the needle 5 of FIGS. 1 to 1 b has been left as it was. It can likewise be seen from this FIG. 1 c that the fibres are transferred from a helical formation to the inlet of this spindle.
A further prior art from the same Applicants is specified in JP 3-10 64 68 (2) and seen in FIGS. 1 d and 1 e , which, by contrast with FIG. 1 , does not exhibit a needle, but rather a truncated cone 5 a with a flat fibre guidance surface, which is a part of the fibre guidance channel 13 , and the tip of which is arranged essentially concentric to the fibre guidance run 7 . The purpose of this cone is the same as that of the tip 5 , namely of producing what is referred to as a false yarn core in order to prevent the fibres from being incorrectly twisted; in other words, that a false twist occurs from the tip backwards against the clamping gap of the output rollers, which would at least in part prevent a true twist of the fibres such as to form the yarn.
SUMMARY
Objects 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 problem was therefore to find a method and device in which the fibres undergo fibre guidance by means of which the fibres can be taken up by the air eddy which is created in such a way that a uniform and firm yarn can be produced.
The problem was resolved in that a fibre guide surface exhibits a fibre delivery edge, over and by means of which the fibres are guided in a formation lying essentially flat next to one another, against an inlet aperture mouth of a yarn guidance channel.
Further advantageous embodiments are provided in the other dependent claims.
The invention is described hereinafter in greater detail on the basis of drawings which represent only some means of implementation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1–1 c Figures from DE 44 31 761 C2, whereby FIG. 1 b corresponds to the device from DE 41 31 059 C2 and FIG. 1 c the device from DE 19 60 32 91 A1, corresponding to figures from JP3-10 63 68 (2);
FIGS. 1 d and 1 e Figures from JP3-10 63 68 (2);
FIG. 2 A first embodiment of the invention essentially according to the section lines I—I ( FIG. 2 b ), whereby a middle element is represented not in section;
FIG. 2 a A section according to the sectional lines II—II of FIG. 2 ;
FIG. 2 b A cross-section according to the section lines III—III of FIG. 2 ;
FIG. 2 c Represents a section taken from FIG. 2 , represented as an enlargement;
FIG. 2.1 The same embodiment as FIG. 2 , whereby the fibre or yarn flow is additionally shown;
FIG. 2 a . 1 Corresponds to FIG. 2 a , whereby the fibre or yarn flow is additionally shown, and a possible modification of the fibre delivery edge is also represented;
FIG. 2 b . 1 Corresponds to FIG. 2 b , whereby the fibre or yarn flow is additionally shown;
FIG. 3 A second embodiment of the invention, essentially according to the section lines I—I from FIG. 3 a;
FIG. 3 a A cross-section according to the section lines III—III of FIG. 3
FIG. 3 b A cross-section corresponding to FIG. 3 a through a first variant of the second embodiment;
FIG. 3 c A cross-section corresponding to FIG. 3 a through a second variant of the second embodiment;
FIG. 3 d A cross-section corresponding to FIG. 3 a through a third variant of the second embodiment;
FIG. 4 A third embodiment of the invention, essentially according to the section lines I—I from FIG. 4 a;
FIG. 4 a A cross-section according to the section lines III—III of FIG. 4 ;
FIGS. 5–5 b A further variant of the invention according to FIGS. 2–2 b;
FIGS. 6–6 b Another variant of the invention according to FIGS. 2–2 b;
FIG. 7 A further variant of the invention according to FIG. 3 ;
FIG. 7 a A cross-section according to the section lines IV—IV of FIG. 7 ;
FIG. 8 A representation of a drafting device as a fibre feed into the element of FIG. 2.1 ; and
FIG. 9 A representation of a fibre releasing device as a fibre feed into the element of FIG. 2.1 .
SUPPLEMENTARY DESCRIPTION OF THE PRIOR ART
FIG. 1 shows a housing 1 with the housing parts 1 a and 1 b and with a nozzle block 2 integrated in it which contains jet nozzles 3 , by means of which an eddy current as described heretofore is created, as well as what is referred to as a needle holder 4 with the needle 5 inserted in it.
As can be seen from FIG. 1 a , the eddy current produces a right-hand swirl in the direction of the arrow (seen looking towards the Figure), and accordingly the fibres F being delivered are conducted in this direction of rotation about the needle 5 against a face side 6 a of what is referred to as the spindle 6 ( FIG. 1 ), and introduced into a yarn passage 7 of the spindle 6 . In this situation, a relatively large distance interval pertains between the nozzle block 2 and the face side 6 a of the spindle, since space must pertain in this distance interval for the needle 5 and its tip.
The fibres F are conveyed in a fibre guidance channel 13 on what is referred to as the fibre guide surface, by way of an aspirated air flow, against the tip of the needle 5 .
The aspirated air flow is created on the basis of an injector effect of the nozzle jets 3 , which are provided in such a way that, on the one hand the air eddy referred to is created, while on the other air is also sucked in through the fibre conveying channel 13 .
This air escapes along a conical section 6 b of the spindle 6 through an air escape cavity 8 into an air outlet 10 .
The compressed air for the jet nozzles 3 is delivered to the jet nozzles in a uniform manner by means of a compressed air distribution chamber 11 .
FIG. 1 b , which represents the prior art to FIGS. 1 and 1 a referred to heretofore, shows that this Figure, by contrast with FIG. 1 a , additionally exhibits a needle holder extension piece 4 a ′, which projects from a face surface 4 ′ and contains the needle 5 ; i.e. the fibres are guided over the entire extension, which pertains because of the contour of the needle holder 4 , against the inlet of the spindle 6 .
FIGS. 1 c to 1 e have already been discussed. In this situation, the identification numbers of these Figures which have not been mentioned do not have any explanation in this application. The disadvantage of these devices lies in the uncertain fibre guidance at a large distance interval from the face side of the needle holder 4 to the inlet mouth aperture 6 c in the face side 6 a of the spindle 6 , as well as in the guidance of the fibres to or about the needle 5 or the cone element 5 a of FIGS. 1 d and 1 e respectively.
DETAILED DESCRIPTION
Reference is now made to embodiments of the invention, one or more examples of which are illustrated in the drawings. The embodiments are provided by way of explanation of the invention, and not meant as a limitation of the invention. It is intended that the invention include modifications and variations to the embodiments described herein.
In order to alleviate certain disadvantages of the prior art devices, according to FIGS. 2–2 c the invention exhibits a fibre delivery edge 29 , which is located very close to an inlet mouth aperture 35 ( FIG. 2 a ) of a yarn guidance channel 45 , which is provided inside what is referred to as a spindle 32 . For a special advantage, a specified distance interval A ( FIG. 2 c ) is defined between the fibre delivery edge 29 and the inlet mouth aperture 35 , and with a specified distance interval B between an imaginary plane E which contains the edge, this plane running parallel to a mid-line 47 of the yarn guidance channel 45 , and this aforesaid mid-line 47 .
In this situation the distance interval A, depending on the fibre type and mean fibre length, and on the relevant experimental results, corresponds to a range from 0.1 to 1.0 mm. The distance interval B depends on the diameter G of the inlet aperture mouth 35 , and, depending on experimental results, lies within a range from 10 to 40% of the diameter G referred to.
In addition to this, the fibre delivery edge exhibits a length D. 1 ( FIG. 2 a ), which is in a proportion of 1:5 to the diameter G of the yarn guidance channel 45 , and is formed by a face surface 30 ( FIG. 2 ) of a fibre conveying element 27 and a fibre guidance surface 28 of the element 27 . In this situation, the face surface 30 , with a height C ( FIG. 2 c ), lies within the range of the diameter G and exhibits an empirically-determined distance interval H between the plane E and the opposite inner wall 48 of the yarn guidance channel 45 .
The fibre conveying element 27 is guided in a carrier element 37 accommodated in a nozzle block 20 , and together with this carrier element forms a free space which creates a fibre conveying channel 26 .
The fibre conveying element 27 exhibits at the inlet a fibre take-up edge 31 , about which the fibres are guided, these being conveyed by a fibre conveying roller 39 . These fibres are raised from the fibre conveying roller 39 by means of a suction air flow from the conveying roller, and conveyed through the fibre conveying channel 26 . The suction air flow is created by an air flow generated in jet nozzles 21 with a blast direction 38 , on the basis of an injector effect.
The jet nozzles, as represented in FIGS. 2 and 2 b , are arranged in a nozzle block 20 on the one hand at an angle β ( FIG. 2 ), in order to create the injector effect referred to heretofore, and, on the other, are offset at an angle α ( FIG. 2 b ), in order to create an air eddy which rotates with a direction of rotation 24 along a cone 36 of the fibre conveying element 27 , and about the spindle front surface 34 ( FIG. 2 a ), in order, as described hereinafter, to form a yarn in the yarn guidance channel 45 of the spindle 32 .
The air flow created by the nozzles 21 in an eddy chamber 22 escapes along a spindle cone 33 , through an air escape channel 23 formed around the spindle 32 , into the atmosphere or into a suction device.
To form a yarn 46 ( FIG. 2 a ), the fibres F which are delivered from the fibre conveying roller 39 , are raised from the fibre conveying roller 39 by means of the suction air flow referred to in the fibre conveying channel 26 , and are guided on the fibre guidance surface 28 in a conveying direction 25 ( FIG. 2 ) against the fibre delivery edge 29 . From this delivery edge, front ends of the fibres are guided through the spindle inlet aperture mouth 35 into the yarn guidance channel 45 , while the rear ends or the rear part 49 of these fibres are folded over as soon as the rear ends are free and taken up by the rotating air flow, so that, with the further conveying of the fibres in the yarn guidance channel 45 , a yarn 46 is created which exhibits a yarn character similar to the ring yarn.
This process is represented in FIGS. 2.1 to 2 b . 1 . It can be seen in these figures that the fibres F delivered with the fibre delivery roller 39 are conducted in the conveying direction 25 on the fibre guidance surface 28 against the fibre delivery edge 29 , and specifically, as shown in FIG. 2 a . 1 , with a converging fibre flow, which tapers increasingly towards the inlet aperture mouth 35 ( FIG. 2 a ). This tapering is applied because the front ends, which are already incorporated into the twisted yarn 46 , have a tendency to migrate in the direction of the tapering, so that front ends of fibres located further to the rear are likewise displaced in the direction of the tapering. This only happens, however, until the rear part 49 of the fibres F have been taken up by the air eddy referred to, and rotated around the spindle front surface 34 and drawn into the inlet aperture mouth 35 at the thread draw-off speed, in the process acquiring the twist necessary for the formation of the yarn.
In FIG. 2 a , the width D. 1 , as shown by the broken lines, is represented in extended form, specifically on the one hand in order to show that the width can be extended, and, on the other, likewise to show that this extended width will, under certain circumstances, reduce the size of the eddy chamber shown in FIG. 2 a , if not even changed with interfering effect, in that the eddy current can no longer develop therein in such a way that the fibre ends 49 can be taken up by the eddy flow with the energy required. This too must be determined by means of empirical experiments.
The yarn formation referred to heretofore takes place after the start of a spinning process of any kind, for example in which a yarn end of an already existing yarn is conducted back through the yarn guidance channel 45 into the area of the spindle inlet mouth aperture 35 sufficiently far for fibres of this yarn end to be opened sufficiently wide by the air flow, which is already rotating, that front ends of fibres which are newly conducted to the fibre guidance channel 26 can be taken up by this rotating fibre sliver and, by repeat drawing of the yarn end which has been introduced, can be held in the sliver such that the following rear parts of the newly-delivered fibres can be wound around the front ends which are already located in the mouth aperture section of the yarn guidance channel, so that, as a consequence, the yarn referred to can be respun with an essentially pre-determined arrangement.
The sequence has been described on the basis of an example in which the front end of a fibre, seen in the direction of conveying, is incorporated in the fibre sliver, and the rear end of this fibre is or becomes free to be “folded over.” The process can, however, take place in an analogous manner in the case of an incorporated rear end of the fibres, whereby the front end is free, and, because of the axial component of the eddy air flow, is deposited at the spindle front surface 34 . The fibre parts which are deposited on the spindle front surface 34 then rotate because of the eddy air flow, and are therefore wound around the fibre ends which have been bound in.
FIGS. 3 and 3 a show a further embodiment of the fibre guidance channel 26 of FIGS. 2–2 c , in this case as the fibre guidance surface 28 . 1 with an elevation 40 arranged at a distance interval M from the fibre delivery edge 29 , over which the delivered fibres slide before they reach the fibre delivery edge 29 . In this situation the distance M corresponds to a maximum of 50% of the mean fibre length.
The elevation exhibits a distance interval N to a fibre guidance surface without elevation, which lies within the range of 10 to 15% of the distance interval M.
The distance intervals M and N are to be determined empirically in accordance with the fibre type and fibre length.
This elevation 40 can exhibit the shapes shown with FIGS. 3 a – 3 d ; i.e. the edge can be concave, according to FIG. 3 b , for example for “slippery” fibres to be explained later, convex according to FIG. 3 c for “sticky” fibres, or, according to FIG. 3 d , wave-shaped. Correspondingly, the fibre guidance surfaces of FIGS. 3 b to 3 d are designated as 28 . 2 , 28 . 3 , and 28 . 4 .
These shapes serve to provide different fibre guidance on the fibre guidance surface 28 . 1 – 28 . 4 , and are to be determined empirically according to the fibre type and fibre length. In this situation, the term “slippery” fibre is understood to mean such as exhibit weak mutual adhesion, and “sticky” fibres such as exhibit a stronger mutual adhesion. The elements which do not have characterization identification correspond to the elements in FIGS. 2 to 2 c.
A further advantage of the elevation lies in the fact that, due to the movement of the fibres over this point, a loosening of possible dirt particles inside the fibre sliver takes place, which are taken up by the conveying air flow and can be conveyed into the open air or into a suction device.
FIGS. 4 and 4 a show a further variant of the fibre guidance surface 28 of FIGS. 2–2 c : fiber guidance surface 28 . 5 . According to this variant, the fibre guidance surface exhibits, at a distance interval P from the fibre delivery edge 29 of a maximum of 50% of the mean fibre length, a depression 41 with a radius R. 1 , whereby the lowest point of the depression 41 is located lower than the edge 29 of FIGS. 2–2 c . In this situation the depression 41 and the radius R. 1 are to be determined empirically on the basis of the fibre type and fibre length, and the depression 41 serves to prevent fibres (short fibres, for example) from moving away sideways, i.e. of being lost as wastage.
As shown in FIG. 4 , this variant can also be combined with the elevation 40 (represented by a broken line) of FIGS. 3 and 3 a or 3 b to 3 d.
The elements which do not have characterization identification correspond to the elements in FIGS. 2 to 2 c.
FIGS. 5–5 b show a further variant of the design of the fibre delivery edge 29 , in that the face surface 30 . 1 exhibits a convex rounding provided with a radius R. 2 , and in this situation the fibre delivery edge 29 acquired a width D. 2 . In this case too, the selection of the radius and the width is a matter of empirical experiments, in order to be able to adapt to the fibre type and fibre length in a way optimum for the yarn formation. In this situation, measures can also be applied to influence the optimization of the eddy chamber 22 from the technical flow point of view, as mentioned earlier.
The elements which do not have characterization identification correspond to the elements in FIGS. 2 to 2 c.
FIGS. 6–6 b show a similar variant concept, inasmuch as, in this case, it is not a convex face side 30 . 1 which is provided for, but a concave face side 30 . 2 , with a radius R. 3 and an edge length of D. 3 . The radius R. 3 and the edge length D. 3 must be determined empirically according to the fibre length and the fibre type. These measures serve to influence the tapering mentioned earlier of the fibre at the inlet aperture mouth.
The elements which do not have characterization identification correspond to the elements in FIGS. 2 to 2 c.
FIGS. 7 and 7 a show a variant of FIGS. 3–3 d , in which the fibre guidance surface consists in this case of a porous place 42 made of sinter material, so that compressed air from a cavity 43 located beneath the porous plate 42 can flow in a very uniform and fine distribution through the porous plate and into the fibres located on this, so that, in a certain sense, a fluidization of the fibres takes place, i.e. a homogenous mingling of air and fibres, which incurs a separation of fibre from fibre, and therefore an increase in the “slipperiness” referred to, i.e. a reduction of the adhesion of the fibres referred to heretofore due to the air located between the fibres.
As a result of this separation, any dirt is more easily loosened and released, with the result that this dirt can be better acquired by the suction air flow at the transition over the intermediate elevation 40 . The compressed air for the cavity 43 is introduced via the compressed air feed 44 .
The pressure in the cavity 43 is to be determined empirically in accordance with the porous plate and the tolerable air outlet speed from the porous surface, and specifically in such a way that the fibres from this air flow is not raised above a tolerable value from the fibre guidance surface.
The porous plate is accommodated by the parts 27 . 1 and 27 . 2 of the fibre conveying element 27 , whereby, because they contain the inlet edge and the fibre delivery edge of the fibres, these parts are made of a material which is more resistant to wear than a porous plate.
FIG. 8 shows a nozzle block from FIG. 2.1 in combination with a drafting device 50 , consisting of the inlet rollers 51 , and apron pair 52 with the corresponding rollers, and the outlet roller pair 53 , which delivers the fibre sliver F to the nozzle block 20 . The fibres leave the drafting device 50 in a plane which contains the clamping line of the outer roller pair. This plane can be offset in relation to the fibre guidance surface 28 in such a way that the fibre sliver is deflected at the fibre take-up edge 31 (see FIGS. 2 and 2 a respectively).
FIG. 9 shows, as an alternative to the drafting device, a device in which a fibre sliver 54 is broken up into individual fibres and in the final stage is delivered by means of a suction roller 62 as a fibre sliver F to the nozzle block 20 of FIG. 2.1 . This device is the object of a PCT application with the number PCT/CH01/00 217 by the same Applicants, to which application reference is made as a constituent part of this application. An alternative can be derived from U.S. Pat. No. 6,058,693.
The fibre sliver break-up device according to FIG. 9 comprises a feed channel 55 , in which the fibre sliver 54 is delivered to a feed roller 56 , whereby the fibre sliver is conveyed onwards from the feed roller 56 to a needle roller or toothed roller 61 , by which the fibre sliver is broken up into individual fibres. A feed trough 57 presses the fibre sliver 54 against the feed roller, in order thereby to feed the fibre sliver in metered fashion to the needle roller or toothed roller 61 . In this situation the hinge 58 and the pressure spring 59 serve to allow for the necessary pressure force.
In the next stage the needle roller 60 transfers the fibres to a suction roller 62 . In this situation the dirt, identified by a T, is separated out.
With the help of the suction force, the suction roller 62 holds the fibres tightly in the area delimited by A to B, seen in the direction of rotation, as far as the clamping point K. After this clamping point, the fibres are released for further conveying in the fibre guidance channel 26 . In the channel 26 , the fibres are acquired by the air flow 25 . The release referred to takes place, for example, because the suction effect on the suction roller 62 is no longer present after the clamping point K, for example because the cover connecting the points A and B (shown in FIG. 9 ) is no longer provided after the clamping point K. The release can, however, be enhanced by means of an air blast B. 2 , which blows through the holes 63 by means of the channel B. 2 . This air blast B. 2 can, however, be dispensed with. The channel B. 2 is supplied with compressed air via the channel B. 1 .
The fibres leave the suction roller 62 in a plane which contains the clamping line K. This plane can be offset in relation to the fibre guidance surface 28 in such a way that the fibre sliver is deflected at the fibre take-up edge 31 (see FIGS. 2 and 2 a respectively).
As far as the drafting device from FIG. 8 is concerned, this is a generally known drafting device system, and it is accordingly not considered in any further detail.
From FIGS. 8 and 9 , it can be seen that the fibre conveying channel 26 is provided with a fibre guidance surface 28 , which is designed without a twist (or without a helix) (see FIGS. 1 a and 1 c respectively). The fibre guidance surface 28 leads to a fibre delivery edge 29 , which is positioned in relation to the inlet aperture mouth 35 of the yarn guidance channel in such a way that the fiber sliver F must come in contact with the edge 29 in order to enter into the inlet aperture mouth 35 . As a result of this, a continuation of a yarn rotation, upstream of the edge 29 , is prevented or at least substantially reduced.
It can be seen from the same figures that the fibre conveying channel 26 is located on the one hand entirely on one side of an imaginary plane (not shown) running perpendicular seen looking towards FIG. 2 , and contains the mid-line 47 of the yarn channel 45 . The fibre conveying channel 26 , on the other hand, is also run close to the inlet aperture mouth 35 of the yarn guidance channel 45 in such a way that, in the combination of the two measures, at least a part of the fibre sliver F must be deflected in order to pass out of the fibre conveying channel 26 into the yarn guidance channel 45 (see FIGS. 1 a and 1 c respectively, where, as a departure to what has gone before, a substantial distance interval pertains between the end of the fibre guidance channel and the spindle, in order to allow for the provision of the needle 5 in the intermediate space).
In the preferred embodiment ( FIGS. 8 and 9 ), the fibre delivery edge 29 of the fibre conveying channel 26 is provided in a plane E ( FIG. 2 c ) parallel to the first plane mentioned, containing the mid-line 47 , said plane being arranged at a predetermined interval B from the plane first referred to.
FIGS. 8 and 9 also show that the fibres which in operation leave the fibre conveying channel 26 enter directly into the area (space 22 , FIG. 2 ) in which the eddy flow is present. This also represents a change in relation to the arrangement according to FIG. 1 , because in this latter arrangement a distance interval pertains between the end of the fibre guidance channel 13 and the plane in which the outlet aperture mouths of the blower nozzles 3 are located.
It should be appreciated by those skilled in the art that modifications and variations can be made to the embodiments described herein without departing from the scope and spirit of the invention as set forth in the amended claims and their embodiments. | A device for the manufacture of a spun thread from a fiber sliver includes a fiber conveying channel with a fiber guidance surface. A yarn guidance channel includes an inlet mouth aperture disposed such that the fiber guidance surface guides fibers to the inlet mouth aperture. A fluid generating device creates eddy currents around the inlet mouth aperture to incorporate individual fibers into an end of a yarn being formed in the yarn guidance channel. The fiber guidance surface includes a fiber delivery edge having a shape and disposed relative to the inlet mouth aperture such that the fibers are guided over the delivery edge and conveyed to the inlet mouth aperture in an aligned generally flat planar formation. | 3 |
This application is a continuation application based on prior copending application Ser. No. 475,052, filed Mar. 14, 1983, method for producing a low density foamed polyester resin.
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for making a low density foam from a polyester resin and more particularly to a method and apparatus for depositing an uncured polyester resin onto a surface to form a foamed polyester resin article.
Techniques have been available for producing polyester resin foams. While the prior techniques purport to produce low density foams, the techniques have only been successful in producing foams having a density of greater than twenty-four pounds per cubic foot. Additionally, these prior techniques are successful in making such foams only on a substantially horizontal surface or in a mold. Examples of such polyester resin foams are those disclosed in three patents to Jacobs et al., U.S. Pat. Nos. 3,920,589, 3,920,590, and 3,920,591. These foam compositions have, however, led to limited commercial interest because of their high cost and impracticality. Moreover, attempts to spray these foams onto a surface or place them into a mold have not always been successful.
Recent advances have been made in connection with low density polyester resin foam utilizing a sulfonyl hydrazide blowing agent in conjunction with promoters, surfactants and other materials. Such foamed resins are disclosed in West et al., U.S. Pat. No. 4,327,196. Attempts to spray even these improved resin foams have also met with limited success, especially when attempts have been made to spray the resin foam with or without glass fiber reinforcement onto a surface that has a vertical component.
SUMMARY OF THE INVENTION
The present invention advances the state of the art by providing methods and apparatus for depositing polyester resins onto a surface to produce foam articles and particularly to produce layers of foam of finite thickness not only on a horizontal mold or mandrel but also on surfaces that have a vertical component and in a mold or on a mandrel. In one of its broadest aspects, the method for making a low density foam from a polyester resin comprises the steps of (a) metering a predetermined amount of a polyester resin from a storage zone to a heating zone, (b) heating the resin to a temperature in the range of from 80° F. to 140° F. in the heating zone, (c) forwarding the heated resin to a first mixing zone, (d) metering a minor amount of a blowing agent to the first mixing zone and mixing the blowing agent with the polyester resin to form an activated resin, (e) forwarding the activated resin to a second mixing zone, (f) metering a minor amount of a catalyst to the second mixing zone and mixing the catalyst with the activated resin to form a catalyzed resin, and (g) immediately thereafter depositing the catalyzed resin on a surface. Preferably a minor amount of a fluorinated hydrocarbon is intermixed with the resin prior to introducing the catalyst into the resin. The blowing agent can comprise sulfonyl hydrazides as well as other suitable materials.
BRIEF DESCRIPTION OF THE DRAWING
A better understanding of the present invention can be derived by reading the ensuing specification in conjunction with the accompanying drawing wherein the FIGURE is a flow chart illustrating the method of the present invention by which low density polyester resin foams are produced.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the FIGURE, liquid ethylenically polyester resin is pumped from a storage tank 10 by a positive displacement pump 12 to a holding tank 14. As discussed in more detail below, the holding tank may be dispensed with depending upon the additives supplied with the original liquid resin. A mechanical mixer is provided in the holding tank 14 for the purpose of mixing additives with the resin. A recirculation conduit leads from the bottom of the tank through a recirculation valve 18 and back to the pump 12. A primary outlet conduit leads to an outlet valve 16. If desired, the outlet valve 16 can be closed while the recirculation valve 18 is opened. In this manner, the material from the holding tank can be recirculated by the pump 12 from the bottom to the top of the tank to facilitate uniform distribution of additives throughout the resin. Any of a variety of conventional mechanical mixers can be effectively employed in the holding tank.
A fluorocarbon gassing agent can be mixed with the resin in the holding tank 14. Fluorocarbon can be stored in a supply container 20, which is pressurized from an inert gas pressure source, such as a nitrogen pressure bottle 22. The inert gas pressure can be maintained in the range of from 55 to 75 psi, preferably at about 65 psi over the fluorocarbon supply. In this manner, the fluorocarbon can be supplied to the holding tank 14 under a pressure that prevents substantial vaporization of the fluorocarbon in the holding tank. Of course, the holding tank must be capable of withstanding ordinary pressures in excess of 75 psi. The holding tank is preferably also fitted with the appropriate pressure relief valves in the event an inordinate overpressure occurs
Fluorocarbon containing resin is pumped by a second positive displacement pump 24 through the outlet valve 16 into labyrinth block heater 26. The heater 26 is preferably of relatively conventional design, employing electrical heating elements that heat an aluminum block defining a labyrinth through which the resin flows. In accordance with the present invention, it is critical that the resin be heated to within the range of 80° F. to 140° F. If the resin is heated higher than 140° F., the resin will prematurely cure, causing major equipment problems as well as causing a deleterious effect on the end product. On the other hand, the resin must be heated to at least 80° F. in order to achieve a relatively quick cure after the resin leaves the resin spray gun. A quick cure is necessary in order to prevent running or sagging of the foamed product on a surface having a vertical component. More preferably, the resin is heated to a heater outlet temperature of between 90° and 130° F.
Another perhaps more important reason for heating the resin is to reduce its viscosity so that the gassing and blowing agents can generate an amount of void sufficient to yield a low density foam. At the same time, care must be taken to retain sufficient resin viscosity and surface tension so that the bubbles or cells in the foam will not contract before the resin cures. Slowing the cell contraction rate is accomplished by providing for a higher viscosity resin that will not immediately contract during the short period of time between occurrence of maximum cell size and resin cure. The viscosity is maintained sufficiently high during this period by only heating the resin to within the temperature ranges set forth above and assuring that the resin cools relatively rapidly once it leaves the gun. The latter can be accomplished by not attempting to build a foam layer that is too thick, e.g., more than about 1 to 2 inches.
The same pump 24 that pumps the resin through the heater 26 also pumps the resin through a stationary mixer 28. A third positive displacement pump 30 meters a blowing agent from a supply tank 32 into the stationary mixer 28. The composition of the blowing agent will be described in greater detail below. A minor amount of the blowing agent is mixed with the heated resin in the stationary mixer. While a variety of stationary mixers are available, it has been found that a mixer described in U.S. Pat. No. 3,286,992, issued Nov. 22, 1966, expressly incorporated herein by reference and sold under the trademark "Static Mixer" by the Kenics Corporation of Danvers, Mass., provides exceptionally through mixing. Stationary mixer as utilized herein means a mixer or mixing system that has no moving parts, that can be placed in a liquid process line, that can be utilized on a continuous basis that is antifouling, but that utilizes very little space.
From the stationary mixer 28, the heated resin combined with the blowing agent is forwarded to a second stationary mixer 34 that is positioned immediately upstream of the spray gun 36. A fourth positive displacement pump 38 meters catalyst from a supply container 40 to the second stationary mixer 34. The heated resin containing the blowing agent must be thoroughly admixed with the catalyst and immediately is fed to the spray gun 36.
Mixing of the resin at this stage of the process is very crucial and somewhat difficult to achieve because of the relative amounts of the materials being mixed and the extreme difference in viscosities. First, very small amounts of catalyst must be thoroughly and uniformly mixed with the resin. Normally, weight ratios of resin to catalyst of from 50:1 to 100:1 are encountered. Moreover, the catalyst normally has a viscosity on the order of 10 cps., while the resin will have a viscosity when heated on the order of 700 to 900 cps. or higher.
It is presently preferred that a series of static-type mixers be employed to achieve the necessary mixing of the catalyst and resin. The preferred mixer first includes a static mixer of the type disclosed in U.S. Pat. No. 3,709,468, issued Jan. 9, 1973, and expressly incorporated herein by reference, into which both the catalyst and resin are introduced. The mixture from the first static mixer is introduced into a segment of a second static mixer of the Kenics type described above. The materials are mixed at pressures on the order of 700 to 1000 psi or greater in less than a second's time. This mixing system maintains turbulent flow and, thus, provides adequate mixing. The mixture is fed from the second static mixer through a conventional spray nozzle forming part of the gun on operator demand and directed toward a surface. Under these conditions, the catalyst and resin are sufficiently mixed prior to leaving the gun so that a uniform cure can be obtained in the foamed resin shortly after the resin is deposited on the surface.
When the operational parameters are maintained within the limits set forth above, and the compositions are maintained within the limits set forth herein, the polyester resin can be sprayed in accordance with the present invention onto horizontal, slanted or even vertical surfaces. The resin immediately foams upon leaving the gun and cures with little or no sagging or running. Thus, a relatively uniform layer of polyester resin foam can be applied, for example, to a glass reinforced resin substrate and sandwiched with another layer of reinforced resin to provide a foam sandwich that has a variety of end uses.
As an alternative to spraying, a low pressure nozzle or pour nozzle can be affixed to the gun. Instead of depositing the material onto a surface by spraying, the resin, mixed and heated in accordance with the present invention, can be deposited or poured into a mold directly from the gun. The resin again will immediately foam to expand and contact the mold surfaces and fill the mold.
If desired, the foam itself can be reinforced with glass fibers. Fiber reinforcement can be accomplished in a conventional manner similar to that employed in combining chopped glass fibers, for example, with conventional nonfoamed resin. Generally, glass fiber roving is taken from a roving supply 42 and advanced to a fiber chopper 44. The fiber chopper is generally physically attached to the resin spray gun 36. Conventional fiber choppers are generally air powered and include a set of rotating blades driven by an air motor. The blades chop the fiber into predetermined lengths and force the chopped fibers in a stream from the chopper into impinging with the resin spray emanating from the spray gun. The resin spray and fibers are thus simultaneously deposited on the surface on which the resin foam is to be formed. The fibers are thus distrubuted throughout the resin foam in a random manner, providing multidirectional reinforcement to the foam structure.
Polyester resins employed in accordance with the present invention to provide low density foams are liquid, unsaturated polyester resins that have a higher viscosity and a higher surface tension than conventional spraying resins. While it is difficult to precisely define high surface tension, resins with a viscosity of 700 to 1000 cps. are preferred while resins having viscosities up to 20,000 cps. can be made to work with the present system. These resins are blended with various ingredients including fluorocarbon gassing agents and specific blowing agents that are described in more detail below. Those resins specifically disclosed in West et al., U.S. Pat. No. 4,327,196, expressly incorporated herein by reference, are especially efficacious in producing the low density polyester foam resins in accordance with the present invention. As disclosed in West et al., in addition to the blowing agents the resins can contain promoters, surfactants, and fillers as well as a wide variety of other additives including flame retardants, stabilizers and the like. Fillers can also be added to the polyester resin either by the resin manufacturer or by the end user of the process disclosed herein by adding the fillers to the holding tank and mechanically admixing them with the resins.
The chemical blowing agents suitable for use in conjunction with the present invention include those disclosed by West et al. as mono-substituted sulfonyl hydrazides. A wide variety of sulfonyl hydrazides may be employed, however, those sold under the trademark "Celogen" by Uniroyal Chemical, a division of Uniroyal, Inc. of Naugatuck, Conn., or those available from Alpha Chemical of Collierville, Tenn. are preferred for use in conjunction with the present invention. Other non hydrazide agents, such as the azo foaming agent sold under the name Lucel 7 and the TBO acid based agent sold under the name Luperfoam 40 by Lucidol, Division of Pennwalt Corporation, are also satisfactory. The sulfonyl hydrazides can be supplied in the form of a liquid or powder. If the sulfonyl hydroazides are supplied in the form of a powder, a liquid carrier is needed to facilitate mixing with the heated resin. A suitable carrier is polyethylene glycol, which has a specific gravity similar to the sulfonyl hydrazides. The celogen is thoroughly mixed in suspension with the polyethylene glycol carrier in a weight ratio of from 1 to 2 to 1 to 1 hydrazide to polyethylene glycol. The blowing agent is preferably combined with the heated resin in a range of from 0.5 to 3.0 weight percent based on the amount of resin. It is most perferred that about 1.0 percent by weight of sulfonyl hydrazide be admixed with the heated resin.
It is important that the catalyst, normally methyl ethyl ketone peroxide be admixed with the heated resin in the spray gun immediately prior to spraying the mixture onto a surface, because the blowing agent and catalyst quickly interact to cause resin cure. In accordance with the present invention, the catalyst is admixed with the heated resin containing the blowing agent in amounts ranging from about 2.0 percent to about 5.0 percent by weight based on the resin. It is most preferred that about 3.0 percent by weight of catalyst be employed.
The fluorocarbon gassing agent is also critical to forming low density foams in accordance with the present invention. Any of a variety of conventional fluorocarbons can be utilized, for example, dichlorofluoromethane, trichlorofluoromethane, and trichlorotrifluoroethane. It is preferred that the fluorocarbon be combined with the polyester resin amounts ranging from about 1.0 percent to about 12 percent by weight based on the resin. It has been found that about 4.0 percent by weight fluorocarbon will provide a foam having a density on the order of from 15 to 25 pounds per cubic foot. Increasing the amount of the fluorocarbon will decrease the foam density. It has been possible to achieve polyester resin foam densities of on the order of about 4 to about 8 pounds per cubic foot in accordance with the present invention utilizing fluorocarbon amounts in the upper end of the foregoing range.
The fluorocarbons can be combined with the resin supplied from a manufacturer in the holding tank 14. If the fluorocarbon is injected into the holding tank immediately below the mixing element, adequate dispersion of the fluorocarbon throughout the resin can be achieved. It has also been found that the fluorocarbons can be admixed with the resin by the resin manufacturer prior to shipping, in amounts up to about 4 to 5 percent by weight while still maintaining a stable end product. Additional fluorocarbon can then be added as desired by the foam manufacturer. Alternatively, the fluorocarbon can be admixed with the resin in a stationary mixer or other suitable mixing system prior to admitting the resin to the heater. In this manner, the amount of fluorocarbon admixed with the resin can be varied as desired to alter the foam density during production.
In addition to the foregoing, it is most desirable to incorporate an emulsifying and thickening agent into the resin. The emulsifying and thickening agent can be introduced into the resin by the resin manufacturer or can be added by the end user by admixing the thickening agent with the resin in the holding tank. A most preferred emulsifying and thickening agent is a sintered colloidal silica. One suitable colloidal silica material is sold under the trademark Cab-O-Sil by the Cabot Corporation of Boston, Mass.
While the present invention has been described in conjunction with a preferred embodiment, one of ordinary skill after reading the foregoing specification will be able to effect various changes, substitutions of equivalents, and other alterations to the methods and composition set forth herein. It is therefore intended that the protection granted by Letters Patent hereon be limited only by the definition contained in the appended claims and equivalents thereof. | A method for producing low density polyester foam includes heating the resin to a temperature in the range of from 80° to 140° F., combining the resin with a blowing agent such as a sulfonyl hydrazide, combining the resulting admixture with a catalyst, and depositing the catalyzed resin on a surface. The density of the resulting foam can be decreased by incorporating a flourinated hydrocarbon into the resin. | 2 |
FIELD OF THE INVENTION
[0001] This application is directed to fragrance materials containing silicones, particularly fragrance materials containing siloxanes in a non-aqueous based fragrance system.
BACKGROUND OF THE INVENTION
[0002] Most fragrance chemicals are hydrophobic materials indicating that they are more soluble in non-aqueous based systems than aqueous systems. For this reason, fragrance compositions are commonly provided in a hydrocarbon base. These hydrocarbon bases comprise materials including alcohols, such as ethanol, and other materials, such as dipropylene glycol and diethyl phthlatae and isopropyl myristate. Higher boiling solvents can also be used in systems depending on the application and are commonly provided in a non-aqueous based systems. Higher temperature applications include plug-in air fresheners where the electric power source can be used to power a heating element to deliver the fragrance chemicals and a higher boiling fragrance solvents. In these situations higher boiling point carriers such as dipropylene glycol ethers are often used as the fragrance chemical solvents.
[0003] Alternatively, an aqueous based system may be employed to deliver fragrance materials. One advantage of an aqueous based fragrance system is the reduced flash point of the fragrance system. In order to make the fragrance chemicals miscible and deliverable in the aqueous system, surfactant and other chemicals are used. For example, U.S. Pat. No. 6,238,646, the contents hereby incorporated by reference, discloses the use of a polymeric emulsion with a dispersed oil phase for the deliverance of atomized oil, such as a fragrance oil, insecticidal oil or medicinal oil. The patent states that the dispersed oil has the benefits of not needing to be shaken before use, is not flammable and does not deposit fragrance on surfaces.
[0004] The deposition of fragrance on surfaces is a problem with many fragrance systems. Controlling the rate of fragrance usage, the particle size of the fragrance as well as insuring that the fragrance remains in the atmosphere is critical. In particular for air fresheners, it is critical that the fragrance not deposit on surfaces such as tables and other surfaces leaving unsightly appearance or damage surfaces.
[0005] Despite the teachings, there is an ongoing need for new fragrance compositions that deliver the desired fragrance in a safe manner that does not deposit fragrance on surfaces after use.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a non-aqueous based fragrance system containing a siloxane oil for the delivery of fragrance chemicals. The fragrance chemical system is particularly well suited for the delivery of fragrance chemicals for air fresheners.
[0007] More specifically the present invention is directed to a liquid, non-aqueous based fragrance containing a siloxane oil at a level of from about 20 to about 30 weight percent of the fragrance composition. Preferably the siloxane oil has a vapor pressure of from about 0.8 to about 1.2 mm Hg (millimeters of mercury).
[0008] In a more preferred embodiment of the invention, a fragrance composition is provided comprising:
[0009] from about 20 to about 30 weight percent of the fragrance composition has a vapor pressure of greater than 0.3;
[0010] from about 15 to about 25 weight percent of the fragrance composition has a vapor pressure of from about 0.1 to about 0.3;
[0011] from about 3 to about 12 weight percent of the fragrance composition has a vapor pressure of from 0.03 to about 0.01; and
[0012] less than about 10 weight percent of the fragrance composition has a vapor pressure of less than 0.01; and a siloxane oil from about 20 to about 30 weight of the fragrance.
[0013] In a highly preferred embodiment of the invention, a fragrance composition is provided comprising:
[0014] from about 23 to about 28 weight percent of the fragrance composition has a vapor pressure of greater than 0.3;
[0015] from about 16 to about 20 weight percent of the fragrance composition has a vapor pressure of from about 0.1 to about 0.3;
[0016] from about 4 to about 6 weight percent of the fragrance composition has a vapor pressure of from 0.03 to about 0.01; and
[0017] less than 5, more preferably from about 0.01 to about 4 weight percent of the fragrance composition having a vapor pressure of less than 0.01; and a siloxane oil from about 23 to about 28 weight of the fragrance.
[0018] The present invention is also directed to a method and apparatus for delivering fragrance from an air freshener, the air freshener containing a heating element preferably with a piezo electric device.
[0019] The above embodiments and other embodiments of the present invention will become apparent from a reading of the following specification and examples.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The selection of the appropriate fragrance materials and non-aqueous carrier of the present invention is critical. The fragrance materials and carriers must have the vapor pressure distribution in order to be effective in the present invention. Failure to provide the appropriate vapor pressure characteristics can lead to the same problems discussed herein above.
[0021] The appropriate carrier materials include but are not limited to alcohols such as ethanol, methanol, and the like; dipropylene glycol, dipropylene glycol ethers, diethyl phthalate and isopropyl myristate. The level of water in these systems is intentionally kept to a minimum, preferably below 5 weight percent of the fragrance composition, more preferably below 1 weight percent and most preferably less than 0.1 weight percent. Persons with skill in the art will be able to formulate fragrance compositions within the scope of the present invention that contain no intentionally added water.
[0022] The level of non-aqueous basis in the fragrance can vary widely from as little as 0.01 to about 50 weight percent of the total fragrance composition. More commonly, the level of the fragrance base is from about 5 to about 30 weight percent, more preferably from about 10 to about 25 and in a highly preferred level from about 15 to about 25 weight percent of the fragrance composition.
[0023] The siloxane materials of the present invention are provided at a level of from 20 to about 30; preferably from about 23 to about 28 and most preferably from about 24 to about 26 weight percent of the fragrance composition.
[0024] The siloxane materials suitable for use in this invention is an organo-silicon polymer with a silicon-oxygen framework with a simplest fundamental unit of (R 2 SiO)n. As used in this application, siloxane materials include both siloxane and silicone materials. The siloxane materials can be straight chains or branched, with multiple branching possible both in the polymer chain as well as in the end groups.
[0025] The siloxane materials that are incorporated in the present invention are typically characterized by their molecular weight. Suitable materials have molecular weights ranging from about 150 to about 400; preferably from about 290 to about 390; and most preferably from about 295 to about 320.
[0026] Siloxane materials that have been found to be suitable in the present invention, include but are not limited to decamethyltetrasiloxane, octamethylcyclotetrasiloxane, hexamethyltetrasiloxane, polydimethylsiloxane, and the like. The most preferred materials for use in this invention are decamethyltetrasiloxane and octamethylcyclotetrasiloxane.
[0027] The vapor pressure of the siloxane-containing fragrance materials of the present invention varies from about 0.5 to about 2, preferably from about 0.8 to about 1.2 and most preferably 1.0. As used in this specification, the vapor pressure of the materials is measured at 25° C. and at 760 millimeters of mercury. Vapor pressure of the materials is measured by ASTM D5191, ASTM D323, ASTM D4953. As used throughout the specification, ASTM is understood to be the test methods promulgated by American Society for Testing Materials, 100 Barr Harbor Drive, PO Box C700, West Conshocken, Pa. 19428. The number following the ASTM name designates the test method for determining the physical parameter. In addition to determining vapor pressures, vapor pressures can be found in various reference books, such as, CRC Handbook of Chemicals and Physics , various editions; and Chemical Properties Handbook , Yaw, Carl L., editor; McGraw-Hill Publishing Company, 1999.
[0028] The viscosity of the fragrance composition, including the non-aqueous base, the fragrance chemicals and the silicon or siloxane materials should be less than about 2 centipoise, preferably from about 0.25 to about 1.5 centipoise, most preferably from about 0.5 to about 1.25 centipoise. Highly preferred fragrance materials have a viscosity of about 1 centipoise as measured at 25° C. and at 25 revolutions per minute using a number 2 spindle.
[0029] The fragrance composition should have a flash point of less than 200° F., preferably from about 140 to about 180 and most preferably from about 140 to about 160° F. Flash point is measured by ASTM D 6450.
[0030] The fragrance chemicals used in the practice of the present invention are not critical as long as the resulting fragrance composition has the vapor pressure distribution recited herein. Of course, the aesthetic consideration of any fragrance composition is critical to the commercial success of the fragrance.
[0031] For example, fragrance chemicals having a vapor pressure of greater than 0.3 mm Hg include but are not limited to: allyl acetone, ethyl amyl ketone, furfural, iso amyl acetate, iso butyl butyrate, methyl furoate, methyl disulfide, propanal, proponol, propyl acetate, hexyl acetate, ethyl acetoacetate, citrus oil distillate, tetrahydrolinalool, and the like.
[0032] Similarly, fragrance chemicals having a vapor pressure of form about 0.1 to about 0.3 include, but are not limited to: allyl caproate, dimethyl octanol, isoamyl crotonate, rose oxide, methyl benzoxalate, methyl heptyl ketone, nonyl aldehyde, benzyl acetate and Vanoris® (IFF) and the like.
[0033] Fragrance chemicals having a vapor pressure of from about 0.03 to about 0.1 mm Hg include, but are not limited to: benzoic acid, cyclohexyl propanol, diethyl succinate, dimethyl octanol, isobutyl caproate, methyl chavicol, oxane, Verdox® (IFF), Vertenex HC® (IFF), phenyl acetaldehyde dimethylacetal, citronellyl acetate and dihydrocarvone and the like.
[0034] Fragrance chemicals having a vapor pressure of from about 0.01 to about 0.03 mm Hg include, but are not limited to: allyl amyl glycolate, anisic alcohol, benzyl isobutyrate, hexenyl isobutyrate, hexyl crotonate, phenoxy ethanol, nonyl alcohol, and the like.
[0035] Fragrance chemicals having a vapor pressure of less than 0.01 mm Hg include, but are not limited to: allyl caproate, anisyl acetate, ethyl anisole, hexyl caproate, Iso E Superb (IFF), methyl iritone, phenoxy ethyl iso butyrate, yara yara, citronellyl acetate, and Vertenex® (IFF) and the like.
[0036] The vapor pressure of fragrance chemicals is available from reference materials such as the CRC Handbook of Chemistry and Physics, various editions; or can be determined by ASTM D5191, ASTM D323, and ASTM D4953.
[0037] Fragrance chemicals are well known in the art. A list of suitable fragrances is provided in U.S. Pat. No. 4,534,891, the contents of which are incorporated by reference as if set forth in their entirety. Another source of suitable fragrances is found in Perfumes Cosmetics and Soaps , Second Edition, edited by W. A. Poucher, 1959. Among the fragrances provided in this treatise are acacia, cassie, chypre, cylamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth, jasmine, lilac, lily, magnolia, mimosa, narcissus, freshly-cut hay, orange blossom, orchids, reseda, sweet pea, trefle, tuberose, vanilla, violet, wallflower, and the like.
[0038] As used in this specification olfactory effective amount is understood to mean the amount of fragrance materials in perfume composition that has an effect on the overall fragrance. As is well appreciated in the art, the individual component will contribute its particular olfactory characteristics, but the olfactory effect of the fragrance will be the sum of the effects of each of the perfume or fragrance ingredients. Thus the fragrance materials can be used to alter the aroma characteristics of the fragrance, or by modifying the olfactory reaction contributed by another ingredient in the composition. The amount will vary depending on many factors including other ingredients, their relative amounts and the effect that is desired.
[0039] The level of siloxane containing fragrance used to scent an article typically varies from about 0.005 to about 20 weight percent, preferably from about 0.5 to about 15 and most preferably from about 1 to about 10 weight percent. Those with skill in the art will be able to employ the desired level of the fragrance compositions of the invention to provide the desired fragrance and intensity to a wide variety of products.
[0040] The use of these compounds is widely applicable in current perfumery products, including the preparation of perfumes and colognes, the perfuming of personal care products such as soaps, shower gels, and hair care products as well as cosmetic preparations. The present invention can also be used to perfume cleaning agents, such as, but not limited to detergents, dishwashing materials, scrubbing compositions, window cleaners and the like.
[0041] The siloxane-containing fragrance materials of the present invention are particularly well suited for use in air fresheners, which are known in the art, see for example U.S. Pat. Nos. 1,994,932; 2,597,195; 2,802,695; 2,804,291; 3,550,853; 4,286,754; 4,413,779; 4,454,987; 4,913,350; and 5,000,383 hereby incorporated by reference.
[0042] The present invention is particularly well-suited for air fresheners that are powered by an electrical source. The electrical source is typically used to power a heating element that promotes the evaporation of the fragrance materials. These devices are also well known in the art, see for example, U.S. Pat. Nos. 3,288,556; 3,431,393; 3,482,929; 3,633,881; 4,020,321; 4,968,487; 5,038,394; 5,290,546 and 5,364,027, incorporated by reference. In a preferred embodiment, the air freshener contains a piezo electric element.
[0043] Well known materials such as surfactants, emulsifiers, extenders can also be employed without departing from the scope of the present invention. The present invention is provided in a liquid form, the fragrance is not encapsulated by a polymer, gelatin or other material that would inhibit the effects the vapor pressure distribution of the fragrance chemicals has on the overall fragrance composition.
[0044] The present invention possesses a number of advantages over previous fragrance compositions. The fragrance materials possess improved evaporative properties, meaning that better droplet formation is created. In addition, the fragrance does not redeposit on surfaces after being released into the atmosphere and the fragrance materials have a flash point that is safe for the materials to be used with devices that contain a heating element.
[0045] In view of the above description and the following example, a person with ordinary skill in the art will understand that other modifications and embodiments may be derived without departing from the spirit and scope of this invention. Unless noted to the contrary, all units set forth below are weight percent.
EXAMPLE 1
[0046] The following fragrance formulation was prepared to demonstrate the distribution of vapor pressure of individual ingredients and relative weight percent suitable for use in the present invention. The fragrance was reported to have a citrus aroma.
VAPOR PRESSURE CHEMICAL (mm Hg) WEIGHT % Decamethyltetramethylsiloxane 1 26.49 (Aldrich Chemical) Hexylacetate 1 2.92 Citrus Oil Dist 0.9 9.79 Ethyl Acetoacetate 0.5 6.16 Tetrahydrolinalool 0.4 5.44 Benzyl Acetate 0.1 14.55 Vanoris ® (IFF) 0.053 3.62 Dihydromyrencol 0.09 5.44 Isobornyl Acetate 0.09 3.62 Linalool 0.05 4.28 Verdox ® (IFF) 0.05 2.46 Vertenex HC ® (IFF) 0.04 3.12 Cyclacet ® (IFF) 0.02 1.08 Phenylacetaldehyde 0.02 1.81 dimethylacetal Citronellyl Acetate 0.01 1.45 Dihydrocyclacet ® (IFF) 0.008 1.08
EXAMPLE 2
[0047] Several fragrance compositions were prepared having the viscosity and flash point set forth below. All vapor pressure values are mm Hg.
Emerald Citus Green Wildflower Apple Ivory Floral Desire Viscosity 1.64 1.97 1.87 1.71 1.63 1.80 1.65 (Centipoise) Flash Point (° F.) 148 150 152 147 145 148 148 Weight percent 26.77 26.44 24.43 27.06 27.4 24.77 27.05 of fragrance chemicals with vapor pressure greater than 0.3 Weight percent 18.70 18.15 14.66 18.82 19.75 17.93 19.35 of fragrance chemicals with vapor pressure between 0.3 and 0.1 Weight percent 19.97 22.03 26.67 22.34 18.10 19.62 20.02 of fragrance chemicals with vapor pressure between 0.1 and 0.03 Weight percent 6.10 6.57 8.30 5.85 2.25 11.68 5.58 of fragrance chemicals with vapor pressure between 0.03 and 0.01 Weight percent 1.10 0.57 0.02 0.50 2.30 0.80 0.80 of fragrance chemicals with vapor pressure less than 0.01 Siloxane oil 26.49 25.00 25.00 25.00 30.00 25.00 27.00 level
[0048] The fragrance compositions were placed in an electrically powered air freshener device. The air freshener device was turned on and the fragrance compositions were provided into the atmosphere. The devices were periodically evaluated for the delivery of fragrance and other criteria.
[0049] It was noted that the floral fragrance had an unacceptably large amount of fragrance that had deposited onto the table surface. It is believed that the level of fragrance materials having a vapor pressure of from 0.01 to 0.03 being 11.68 weight percent was the cause. This fragrance composition does not have the vapor pressure distribution recited in the claims. The other fragrance compositions delivered the fragrances to the atmosphere in a satisfactory manner without the problem of the fragrance chemicals redepositing on the tabletop. The other fragrances had the vapor pressure distribution and siloxane oil levels recited in the claims. | Non-aqueous based fragrance compositions containing a siloxane material are disclosed. The fragrance compositions are suitable for many applications including cosmetics, laundry care and personal care items. The fragrance compositions can also be used in air fresheners, particularly those air fresheners that contain heating elements. | 0 |
This is a continuation of PCT/JP06/323310 filed Nov. 22, 2006 and published in Japanese.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a radio base station for performing radio communication with a mobile terminal, and particularly to a radio base station for performing so-called transmission power control of inserting a power control (TPC: Transmitter Power Control) command into transmission data so that reception quality of signals from a mobile terminal is constant, and also adjusting transmission power by a TPC command from the mobile terminal, and a control method thereof.
2. Description of the Related Art
The construction of a radio base station for performing transmission power control using a prior art will be described with reference to FIG. 8 by exemplifying a W-CDMA (Wide Band—Code Division Multiple Access) system. FIG. 8 is a block diagram showing the construction of a conventional radio base station.
As shown in FIG. 8 , the conventional radio base station is equipped with base band transmitting/receiving parts 11 , 12 , 13 , . . . for performing base band transmission/reception of each call under the control of a base station, and a channel (CH) multiplexing part 21 for multiplexing channels and outputting a base band (BB) transmission signal.
The base band transmitting/receiving part 11 takes charge of a channel zero (#CH 0 ), the base band transmitting/receiving part 12 takes charge of a channel 1 (#CH 1 ), and the base band transmitting/receiving part 13 takes charge of a channel 2 (#CH 2 ).
Each base band transmitting part comprises an encoding part 101 for encoding transmission data, a frame generating part 102 for inserting a pilot symbol for synchronous detection and a TPC command into the encoded transmission data, a modulating part 103 for performing primary modulation such as QPSK (Quadrature Phase Shift Keying), 16 QAM (16-positions Quadrature Amplitude Modulation) or the like, a spreading part 104 for performing spreading modulation by using a spreading code of each call, a power control part 105 for determining a power value of each call, a power setting part 106 for multiplying the spread signal of each call by the power value determined in the power control part 105 , de-spreading parts 107 - 1 , 107 - 2 for performing de-spreading from a reception signal by using a reference code of each call and extracting the reception signal of the call, detecting parts 108 - 1 , 108 - 2 for subjecting the extracted reception signal of each call to synchronous detection, an SIR measuring part 109 for measuring reception quality (SIR: Signal to Interference Ration: the ratio of desired wave power to interfering wave power) of the extracted reception signal of each call, an insertion TPC generating part 110 for determining an insertion TPC command from the measured SIR, a TPC judging part 111 for judging the TPC command out of the synchronously-detected reception signal, a data judging part 112 for judging transmission data out of the synchronously-detected reception signal, and a decoding part 113 for decoding the judged transmission data.
Furthermore, the CH multiplexing part 21 is a site for adding and multiplexing transmission-processed data of each call.
The operation of the conventional radio base station shown in FIG. 8 , particularly, the operation associated with the transmission power control will be described.
First, the transmission data encoded in the encoding part 101 is input to the frame generating part 102 . In the frame generating part 102 , the synchronous detection pilot system and the TPC command are inserted into the transmission data.
As shown in FIG. 9 , the pilot symbol and the TPC command are inserted at a period of one slot (slot) of the transmission signal. FIG. 9 is a diagram showing an example of the frame construction of a downlink (Downlink: DL) and an uplink (Uplink: UL). In FIG. 9 , p represents a pilot symbol, d represents a data symbol and t represents a TPC command.
With respect to the pilot symbol, a unique symbol for which a slot number allocated on the basis of the system timing of the call concerned has been already known at both the base station and the terminal is inserted.
With respect to the TPC command, for example, SIR is measured from the received pilot symbol of a call A (UL) of FIG. 9 , and the insertion TPC command is determined and generated in accordance with the measurement result in the insertion TPC generating part 110 . In general, a reference SIR and the measured SIR of the call concerned are compared with each other, and the following commands are generated:
in case of measured SIR>reference SIR, DOWN command, or
in case of measured SIR<reference SIR, UP command.
The generated insertion TPC command is inserted into the next one slot of the transmission signal of the call A (DL) in the frame generating part 102 , and the framed transmission data are modulated in the modulating part 103 , spread in the spreading part 104 , and input to the power setting part 106 .
The received BB signal is de-spread in the de-spreading parts 107 - 1 , 107 - 2 by the reference code of the call concerned, and subjected to the synchronous detection in the detection parts 108 - 1 , 108 - 2 . With respect to the TPC command, the judgment of the TPC command symbol is made in the TPC judging part 111 , and with respect to the data symbol, the judgment of data is made in the data judging part 112 .
The data judged in the data judging part 112 are decoded in the decoding part 113 , whereby reception data can be obtained.
Furthermore, the TPC command judged in the TPC judging part 111 generally has “power UP”, “power DOWN” information, and on the basis of a judgment result in the TPC judging part 111 , the power control part 105 determines power of +1 dB for the present power value in case of “power UP” and −1 dB in case of “power DOWN”.
The determined power value is reflected at a timing as shown in FIG. 9 , multiplied by the transmission data in the power setting part 106 and then output. The transmission data which are bit-expanded by the power value of each call are multiplied in the CH multiplexing part 21 and output.
JP-A-2005-159495 “TRANSMISSION POWER CONTROL METHOD” (see Patent Document 1) is known as a prior art concerning transmission power control in DS-CDMA (Direct Sequence Code Division Multiple Access) assuming that so-called transmission power control of adjusting transmission power from a counter station so that reception quality from the counter station is constant is carried out at some transmission/reception station.
Patent Document 1: JP-A-2005-159496
The above operation is carried out for plural calls in the radio base station. In this case, there is the following problem.
The problem will be described with reference to FIGS. 10 and 11 . FIG. 10 is a schematic diagram showing the frame construction when a frame boundary of each call has an offset to a system timing relatively, and FIG. 11 is a schematic diagram showing the frame construction when the frame boundary of each call is coincident with the system timing.
In the case shown in FIG. 10 , the permissible power setting time and the insertion TPC generating time of each call likewise has an offset to the system timing, and in other words, it equivalently means that the processing load of each call which is effective to the permissible time is dispersed.
On the other hand, in the case of FIG. 11 , the permissible power setting time and the insertion TPC generating time of each call are completely coincident, and thus this equivalently means that the effective processing time of each call to the permissible time is required to be short, that is, the load is concentrated.
When the system permits this condition, high-speed processing must be executed so as to adapt to the load concentration. For example, when it is assumed that the above processing is executed by using a signal processing processor, it is considered that a high-speed processor which can also adapt to the load concentration is used.
However, there is a problem that a higher speed processor is more expensive.
Furthermore, as the processing construction of the above processing, when the processing is executed under the condition that the processing amount per unit time is determined, for example, there are two calls during one symbol time, there occurs a problem that the permissible time can be kept for some call, but the permissible time cannot be kept for another call. When the permissible time cannot be kept, parasitic oscillation caused by so-called power control delay occurs, and the reception quality is deteriorated at both the base station side and the terminal side.
The insertion TPC processing of FIG. 8 is executed in the frame generating part 102 , and the modulation processing in the modulating part 103 , the spreading processing in the spreading part 104 and the power setting processing in the power setting part 106 are sequentially executed subsequently to the frame generating processing.
That is, with respect to the timing at which the TPC command is inserted, in consideration of the processing time of the modulation, the spreading, the power setting, etc., this processing is required to be executed much earlier. This effectively means that the permissible insertion TPC generating time of FIG. 9 is further shorter, and thus the above problem when the load is concentrated is estimated to be more serious.
SUMMARY OF THE INVENTION
The present invention has been implemented in view of the foregoing situation, and has an object to provide a radio base station for relaxing load concentration of power control by a simply method and also relaxing control delay, and a control method thereof.
In order to solve the problem of the above prior art, according to the present invention, a radio base station that inserts a power control command into transmission data so that reception quality of signals from a mobile terminal is constant and adjusts transmission power on the basis of the power control command in reception data from the mobile terminal comprises: a quality measuring part for measuring the quality of a reception signal; a power control command insertion status control part for controlling a condition for determining a power control command to be inserted into transmission data; a power control command determining part for determining the power control command to be inserted on the basis of the measured quality of the reception signal and the condition for determining the power control command; a detecting/judging part for synchronously detecting and judging the power control command from the reception data; a power setting status controller for controlling a condition for determining transmission power for a call; a power determining part for determining a transmission power value for the call concerned on the basis of the judged power control command and the condition for determining the transmission power; a frame generating part for inserting a pilot symbol for synchronous detection and a dummy power control command into encoded transmission data to generate a frame; a modulating part for subjecting the frame-generated transmission data to primary modulation; a spreading part for performing spreading modulation by using a spreading code of each call; and a power setting part for multiplying the transmission power value determined in the power determining part by a signal which is subjected to spreading modulation every call. Therefore, the processing in the power control command determining part to which real-time performance is required can be delayed by the amount corresponding to the processing time of the frame generating part, the modulating part and the spreading part by setting the power control command in the power setting part, and even when the processing to which real-time performance is required is concentrated, the load can be dispersed.
Furthermore, according to the present invention, in the radio base station, the power setting part has a function of inverting the sign of the transmission power value in accordance with the inserted power control (TPC) command when the transmission data are the timing at the power control (TPC) command to be timely inserted.
According to the present invention, in the radio base station, the determination of the power control command in the power control command determining part and the determination of the transmission power value in the power determining part are carried out at the timing of each call, and the control processing in the power control command insertion status control part and the control processing in the power setting status control part are executed on all calls under the control of the base station collectively or while the number of calls to be processed per unit time is determined.
According to the present invention, a method of controlling a radio base station that inserts a power control command into transmission data so that reception quality of signals from a mobile terminal is constant, and adjusts transmission power on the basis of the power control command in reception data from the mobile terminal comprises: inserting a fixed symbol serving as a power control command as a dummy irrespective of the quality of a reception signal measured in a quality measuring part, generating timing information for identifying a symbol in which the power control command as the dummy is inserted and outputting the timing information to the power setting part by a frame generating part; modulating framed transmission data by a modulating part; spreading the transmission data in a spreading part; and setting the power control command corresponding to the quality of the reception signal measured in the quality measuring part on the basis of the timing information and subjecting the spread transmission data to power setting by a power setting part. Accordingly, the processing in the power control command determining part to which real-time performance is required can be delayed by the amount corresponding to the processing time of the frame generating part, the modulating part and the spreading part by setting the power control command in the power setting part, and even when the processing to which real-time performance is required is concentrated, the load can be dispersed.
According to the present invention, in the radio base station control method, the power determining part determines a transmission power value, and the power setting part inverts the sign of the transmission power value in accordance with the power control command.
According to the present invention, in the radio base station control method, the power control command determining part executes the processing of determining the power control command corresponding to the quality of the reception signal measured in the quality measuring part at the timing of each call, the power determining part executes the processing of determining the transmission power value at the timing of each call, the power control command insertion status control part executes the control processing on all the calls under the control of the base station collectively or while the number of calls to be processed per unit time is determined, and the power setting status control part executes the control processing on all the calls under the control of the base station collectively or while the number of calls to be processed per unit time is determined. Accordingly, the processing in the power control command determining part and the processing in the power determining part to which real-time performance is required, and the control processing of the power control command insertion status control part and the control processing of the power setting status control part to which real-time performance is not required can be separately executed at different timings, and the load concentration of the processing to which real-time performance is required can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the construction of a radio base station according to an embodiment of the present invention.
FIG. 2 is a block diagram showing the construction of a power setting part.
FIG. 3 is a diagram showing an example of TPC command symbol mapping in QPSK modulation.
FIG. 4 is a diagram showing a condition content for determining transmission power.
FIG. 5 is a diagram showing a processing example of a power setting status control part and a power determining part.
FIG. 6 is a diagram showing a condition content to determine insertion TPC.
FIG. 7 is a diagram showing a processing example of a TPC insertion status control part and an insertion TPC determining part.
FIG. 8 is a block diagram showing the construction of a conventional radio base station.
FIG. 9 is a diagram showing a frame construction example of a downlink (DL) and an uplink (UL).
FIG. 10 is a schematic diagram showing the frame construction when a frame boundary of each call has an offset to a system timing relatively.
FIG. 11 is a schematic diagram showing the frame construction when the frame boundary of each call is coincident with the system timing.
DESCRIPTION OF REFERENCE NUMERALS
11 , 12 , 13 , 51 , 53 . . . base band transmitting/receiving part, 101 , 501 . . . encoding part, 102 , 502 . . . frame generating part, 103 , 503 . . . modulating part, 104 , 504 . . . spreading part, 105 . . . power control part, 106 . . . power setting part, 107 - 1 , 107 - 2 . . . de-spreading part, 507 - 1 , 507 - 2 , de-spreading part, 108 - 1 , 108 - 2 . . . detecting part, 508 - 1 , 508 - 2 . . . detecting part, 109 , 509 . . . SIR measuring part, 110 . . . insertion TPC generating part, 510 . . . insertion TPC determining part, 111 , 511 . . . TPC judging part, 112 , 512 . . . data judging part, 113 , 513 . . . decoding part, 21 , 61 . . . CH multiplexing part, 71 . . . power setting status control part, 81 . . . TPC insertion status control part
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment according to the present invention will be described with reference to the drawings.
In a radio base station and a control method of the radio base station according to this embodiment of the present invention, a TPC command as a dummy is inserted in a frame generating part, and setting of the TPC command is carried out in a power setting part. Therefore, the processing of determining a TPC command to be inserted can be delayed by the amount corresponding to the processing time of the frame generating part, a modulating part and the spreading part, and thus even when the processing is concentrated, the load can be dispersed.
Furthermore, in the radio base station of this embodiment of the present invention, the processing of determining the TPC command and the processing of determining the power value to which real-time performance is required, and the control processing of the TPC command insertion status and the power setting status control processing to which no real-time performance is required are executed separately from each other at different timings, so that the concentration of the load imposed on the processing to which the real-time performance is required can be reduced.
The construction of the radio base station according to the embodiment of the present invention will be described with reference to FIG. 1 . FIG. 1 is a block diagram showing the construction of the radio base station according to the embodiment of the present invention.
As shown in FIG. 1 , the radio base station (this base station) of the embodiment of the present invention has base band transmitting/receiving parts 51 , 52 , 53 , . . . for performing base band transmission/reception of each call under the control of the base station, a channel (CH) multiplexing part 61 for multiplexing channels and outputting a base band (BB) transmission signal, a power setting status control part 71 for controlling a condition for determining transmission power, and a TPC insertion status control part 81 for controlling a condition for determining an insertion TPC command.
The base band transmission/reception part 51 takes charge of a channel zero (#CH 0 ), the base band transmitting/receiving part 52 takes charge of a channel 1 (#CH 1 ) and the base band transmitting/receiving part 53 takes charge of a channel 2 (#CH 2 ).
Each base band transmitting/receiving part comprises an encoding part 501 for encoding transmission data, a frame generating part 502 for inserting a pilot symbol for synchronous detection and a TPC command as a dummy into the encoded transmission data, a modulating part 503 for performing primary modulation such as QPSK, 16 QAM or the like, a spreading part 504 for performing spreading modulation by using a spreading code of each call, a power determining part 505 for determining a power value of each call and outputting the power value, a power setting part 506 for multiplying the spreading signal of each call by the power value determined in the power determining part 505 , de-spreading parts 507 - 1 , 507 - 2 for performing de-spreading from the reception signal by using a reference code of each call to extract the reception signal of the call, detecting parts 508 - 1 , 508 - 2 for subjecting the extracted reception signal of each call to synchronous detection, an SIR measuring part 509 for measuring reception quality (SIR) of the extracted reception signal of each call, an insertion TPC generating part 510 for determining an insertion TPC command from the measured SIR, a TPC judging part 511 for making a judgment concerning the TPC command out of the synchronously detected reception signal, a data judging part 512 for making a judgment concerning transmission data out of the synchronously detected reception signal, and a decoding part 513 for decoding the judged transmission data.
The CH multiplexing part 61 is a site for adding and multiplexing data of each call which has been subjected to the transmission processing. The power setting status control part 71 is a site for controlling a condition for determining transmission power for a call under the control of the radio base station.
The TPC insertion status control part 81 is a site for controlling a condition for determining a TPC command to be inserted for a call under the control of the radio base station.
Next, the operation in the base station will be described with reference to FIG. 1 .
The transmission data encoded in the encoding part 501 are input to the frame generating part 502 .
In the frame generating part 502 , a pilot symbol for synchronous detection and a dummy TPC command are inserted into the transmission data. The pilot symbol and the TPC command are inserted at one slot period of transmission signal as in the case of the prior art. A unique symbol for which a slot number allocated on the basis of the system timing of the call concerned has been already known in both the base station and the terminal is inserted as the pilot symbol.
In the embodiment of this invention, with respect to the TPC command inserted in the frame generating part 502 , a fixed symbol is inserted as a dummy irrespective of the measured SIR. Furthermore, the frame generating part 502 generates insertion TPC timing information so that a dummy TPC-command inserted symbol can be identified, and outputs the insertion TPC timing information to the power setting part 506 . The framed transmission data are modulated in the modulating part 503 , subjected to spreading in the spreading part 504 and then input to the power setting part 506 .
In the power setting part 506 , the setting of power and the insertion of the TPC command are performed.
Here, the method of inserting the TPC command in the power setting part 506 will be described with reference to FIG. 2 . FIG. 2 is a block diagram showing the construction of the poser setting part.
In FIG. 2 , an insertion TPC judging part 601 judges whether the TPC information to be inserted (insertion TPC information) which corresponds to an output from the insertion TPC determining part 510 is “power UP instruction” or “power DOWN instruction”.
A switch part 602 performs a switching operation between the output “−1” if the judged insertion TPC information indicates “power DOWN instruction” and the output “+1” if the judged insertion TPC information indicates “power UP instruction”.
A multiplier 603 multiplies the power setting value corresponding to the output of the power determining part 505 by the output of the switch part 602 to allocate a sign to the power setting value.
The multiplying part 604 multiplies the “+” or “−” sign allocated power setting value by the spread signal from the spreading part 504 , and outputs the spread signal after the power setting.
As described above, the TPC command symbol inserted in the frame generating part 502 is a dummy, and it is a fixed symbol. If QPSK is assumed as primary modulation and an example as shown in FIG. 3 is assumed, the TPC symbol may take any one of (1) and (2). FIG. 3 is a diagram showing an example of the TPC command symbol mapping in QPSK modulation.
The insertion TPC timing information is input from the frame generating part 502 , the switch 602 is operated on the basis of the insertion TPC command judgment result when the TPC insertion timing comes, the sign is allocated to the power setting value in the multiplier 603 , +(power setting value) or −(power setting value) is output.
If the TPC command to be inserted as a dummy is assumed to be an UP command (( 1 ) of FIG. 3 ), the insertion TPC command is inverted by the multiplication of the multiplier 604 to be a phase point of ( 2 ) of FIG. 3 when the value of the output of the multiplier 603 is equal to −(power setting value).
Conversely, when the value of the output of the multiplier 603 is equal to +(power setting value), the insertion TPC command is kept to the phase point of ( 1 ) of FIG. 3 even after the multiplication of the multiplier 604 .
In the base station, the insertion TPC timing can be delayed more effectively than the prior art.
The received BB signal is de-spread by using the reference code for the cal concerned in the de-spreading parts 507 - 1 , 507 - 2 , and subjected to synchronous detection in the synchronous detection parts 508 - 1 , 508 - 2 . The TPC command symbol is judged in the TPC judging part 511 , and the data symbol is judged in the data judging part 512 . The data judged in the data judging part 512 is decoded in the decoding part 513 to obtain the reception data.
Here, transmission power control mans in the base station will be described with reference to FIGS. 4 to 7 .
FIG. 4 is a diagram showing a condition content for determining transmission power, FIG. 5 is a diagram showing processing examples of the power setting status control part and the power determining part, FIG. 6 is a diagram showing a condition content for determining the insertion TPC, and FIG. 7 is a diagram showing processing examples of the TPC insertion status control part and the insertion TPC determining part.
As the condition for determining the transmission power shown in FIG. 4 , the power setting status control part 71 “judges” the “condition” to an “input”, and when the “judgment” result is output to the power determining part 505 , it controls to establish the “state” based on the “judgment” result.
That is, when the information indicated in an “input” column or the like is input to the power setting status control part 71 , a judgment concerning the condition corresponding to the information as shown in a “condition, judgment” column, and the state is controlled in the power determining part 505 on the basis of the judgment result to the condition as shown in a “status” column.
The power setting status control part 71 judges the priority of each state or whether the state is achievable or unachievable on the system, selects any one of the statuses of enforced power increase control, power value hold (keep) control, ±1 dB control based on the judgment TPC, ±2 dB control based on the judgment TPC, transmission OFF and outputs it as a power setting status as shown in FIG. 5 .
The operation is carried out on the basis of the power setting status in the power determining part 505 .
For example, when the ±1 dB control status based on the judgment TPC is indicated, the calculation and determining processing of the power setting value in the call concerned is carried out at the timing of the call concerned by using the judgment TPC and the reference power value to determine and renew the present power setting value.
As described with respect to the above example, the processing (control) concerning the determination of the power value is separated into the processing in the power determining part 505 , etc. to which real-time performance is truly required as a portion at which the processing is not executed unless the result of the judgment TPC has been known, and the processing in the power setting status control part 71 as a portion to which real-time performance is not required because it has been known in advance.
As the condition for determining the insertion TPC shown in FIG. 6 , the TPC insertion status control part 81 “judges” a “condition” to an “input” in, and when the “judgment” result is output to the insertion TPC determining part 510 , it controls the insertion TPC determining part 510 to establish the “state” based on the “judgment”.
FIG. 7 shows the processing when the insertion TPC is determined, and FIG. 7 shows an example of the condition for determining the insertion TPC in W-CDMA.
On the basis of the input of FIG. 6 , the TPC insertion status control part 81 makes a judgment concerning the condition in FIG. 6 , and settles each state. It judges the priority of each state or whether the state is achievable or unachievable, and selects any one of statuses of insertion of the inverted output to the previous output, insertion of an enforced UP command, insertion of the comparison result between Target SIR and the measured SIR measurement result and non-insertion, and outputs it as a TPC insertion status as shown in FIG. 7 .
The operation is carried out on the basis of the TPC insertion status in the insertion TPC determining part 510 .
For example, when the comparison result between the Target SIR and the SIR measurement result indicates the insertion status, the calculation and determining processing of the insertion TPC in the call concerned is carried out at the timing of the call concerned by using the measured SIR and the Target SIR to determine and renew the insertion TPC.
As described with respect to the above example, as in the case of the power setting processing, with respect to the processing of the insertion TPC, the processing (control) concerning the determination of the insertion TPC is separated into the processing in the insertion TPC determining part 510 , etc. to which real-time performance is truly required as a portion at which the processing is not executed unless the measurement result of SIR has been known, and the processing in the TPC insertion status control part 81 as a portion to which real-time performance is not required because it has been known in advance.
The transmission power control processing for plural calls when the processing is separated into the processing (control) to which the real-time performance is truly required, and the processing (control) to which the real-time performance is not truly required because it has been known in advance, will be described.
By utilizing the fact that the power setting status control processing and the TPC insertion status control processing to which the real-time performance is not truly required have been known in advance, for example, the processing can be collectively executed on the plural calls in accordance with the load status of a processor in advance, and the load can be dispersed by uniquely determining the number of calls to be processed per unit time. As a result, this contributes to reduce the concentration degree of the processing to which the real-time performance is truly required, and the problem that the permissible-time regulation-unreachable problem due to the load concentration is relaxed.
As described above in detail, by the construction of the base station and the transmission power control procedure, the load of the power control processing can be dispersed, and also the effective permissible time for the generation of the insertion TPC can be increased.
The present invention is suitably used for a radio base station for relaxing load concentration of power control and relaxing control delay by a simple method, and a method of controlling the radio base station. | To provide a radio base station and a control method thereof wherein a simple way is used to relax the load concentration of a power control and also relax the control delay. A radio base station and a control method thereof wherein a frame generating part inserts a dummy TPC command, and a power setting part sets a TPC command, whereby a process of deciding the TPC command to be inserted can be delayed by the time required for the processes done in the frame generating part, a modulating part and a spreading part and wherein the process of deciding the TPC command and a process of deciding a power value are separated from and done at different timings from a process of controlling a TPC command insertion status and a process of controlling a power setting status, with the result that even when the processes are concentrated, a load dispersion can be done. | 7 |
The present invention is directed generally to an apparatus and a method for recovering oil from the surface of a body of water.
BACKGROUND OF THE INVENTION
In these days of giant oil tankers plying the seas there is an increasing danger of spillage of crude oil onto the surface of the oceans or inland waterways either through accident or mistake. There have already been enough such spillages for environmentalists to see that the damage to the ecology can be devastating when a spillage occurs and the spilled oil reaches shore. Additionally, the economic consequences of oil spillages are far-reaching, both from the standpoint of the losses incurred and the expense of attempting to recover the oil.
There have been many attempts at achieving an effective apparatus which will economically and efficiently recover oil following a spill. Such apparatus should be economical to produce, be readily transportable to the spill site, be relatively easy to operate and be efficient in its operation Several versions of oil skimming devices have been tried, such devices using a conveyor or other such apparatus to convey oil from the water surface upwardly to a waiting tank. Crude oil is extremely viscous and has the unwelcome property of sticking securely to almost anything it contacts. This leads to unending problems with conveyor-type recovery devices as they soon become clogged or bound by the oil itself.
One attempt at utilizing the properties of crude oil for recovery thereof is found in Canadian Pat. No. 998,624 issued Oct. 19, 1976 to Olsen. That patent teaches the utilization of a number of floating cells having openings adjacent the top through which an oil/water mixture passes by wave action into the cells. The mixture is pumped from each cell to a holding tank on board a ship or a barge. In the holding tank the oil floats to the top and uncontaminated water is returned to the sea through a ball float control valve by gravity. This device thus makes use of the lower specific gravity of the oil to achieve separation but it also has drawbacks. For example there is no control over the amount of oil/water mixture entering the cells as dependence is made on wave action to cause the mixture to enter the cells. Also the action of the cells and the subsequent pumping operation will result in unwanted emulsification of the oil in the water, making separation more difficult.
SUMMARY OF THE INVENTION
The present invention is similar to that of Canadian Pat. No. 998,624 in that it utilizes the lower specific gravity of the oil to achieve separation. However, the present invention permits a controlled flow of oil/water mixture to a recovery unit, not being dependent on wave action; does not require a separate ship or barge to carry a holding tank; and reduces the chance of emulsification of the oil, permitting more efficient recovery thereof.
The present invention utilizes a collection unit which very simply entails a vertically oriented retaining wall of generally U-shape which funnels the oil/water mixture from the mouth thereof as it is towed through the water to a concentration area defined by the wall. A recovery unit is towed by the collection unit and entails a vertically oriented open ended cylinder having portions above and below the water surface. A conduit leads from below the concentration area and exits into the lower portion of the cylinder, below the water surface, the conduit being oriented to induce a circular flow within the cylinder. A pump in the conduit draws the oil/water mixture from the concentration area and pumps it to the cylinder. In the cylinder the oil floats to and accumulates on the surface of the water therein and uncontaminated water is forced out of the open lower end of the cylinder. Proto-types of the invention have shown that there is very little emulsification of the oil and hence almost 100% recovery of oil from the oil/water mixture passed therethrough. There is control of the amount of oil/water mixture passed through the apparatus and of course there is control of the passage of the apparatus through the oil spill as the apparatus may be towed by an oil spill containment boom and the boats deploying it. Once the cylinder is full it may be replaced by an "empty" recovery unit or it may be emptied into any suitable larger receptacle as might be contained in, for example, a tanker ship or barge.
Broadly speaking therefore the present invention may be seen as providing a method of recovering oil from the surface of a body of water including the steps of: (a) moving apparatus comprising a collection unit defining a concentration area therein, a recovery unit having a vertically oriented open ended cylinder mounted therein with upper and lower portions extending above and below the water surface respectively, and a submerged pumping unit including a pump-containing conduit leading from the concentration area to an opening in the lower portion of the cylinder, through the oil contaminated water; (b) operating the pump to draw an oil/water mixture from the concentration area into the conduit; (c) continuing operation of the pump to force the oil/water mixture through the conduit and into the cylinder; and (d) flowing the oil/water mixture generally tangentially into the cylinder below the water surface whereby oil from the mixture will rise to and accumulate on the surface of water within the cylinder and uncontaminated water will flow downwardly through the lower open end of the cylinder.
The above method may be effectively carried out in accordance with the present invention by way of apparatus for recovering oil from the surface of a body of water comprising a collection unit, a pumping unit and a recovery unit, the collection unit including means for deflecting an oil/water mixture into a concentration area therein, the recovery unit including generally vertically oriented open ended holding means having a lower submerged portion, and the pumping means including submerged conduit means leading from the concentration area to an opening in the submerged portion of the holding means and containing pump means therein operable to continuously draw a quantity of the oil/water mixture from the concentration area and to feed the quantity through the conduit means to the holding means, whereat oil floats to and accumulates on the surface of water in the holding means and uncontaminated water exits from the open lower portion of the holding means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation, partly in cross-section of an oil spill recovery apparatus of the present invention.
FIG. 2 is a plan view of the apparatus depicted in claim 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Structure
The oil recovery system of the recovery invention is designated by the reference number 10 and it includes three basic components, namely a collection unit 12, a recovery unit 14 and a pumping unit 16. The collection unit 12 is connected via the pumping unit 16, to the recovery unit 14.
The collection unit 12 will be described first of a11 with reference to both figures of the drawings. A retaining wall 18 is shown as being vertically oriented and as extending above and below the water line W. The retaining wall has a generally U-shape and is made up of a pair of opposed side walls 20 which may be parallel to each other or may diverge outwardly from the curved wall 22 which connects the walls together along one vertical edge thereof. The opposite vertical edges of the walls 20 define therebetween an open mouth area M which is spanned by a coarse mesh screen 24 which has upper and lower portions above and below the water line respectively to inhibit the entry of debris into the collection unit while still permitting the oil on the water to pass into the collection unit. At the water surface and generally in the vicinity of the center of curvature for the curvcd end wall 22 is a concentration area C, the significance of which will become more readily apparent hereinbelow.
A flotation boom 26 extends along the outer surface of the retaining wall 20 and is intended to maintain the retaining wall in its preferred orientation as discussed above. The flotation boom is generally rectangular in cross-section and may take the form of a metal casing containing flotation material such as an expanded cellular foam. By using a metal casing to contain the flotation material it is possible to attach other elements to the boom 26 and the flotation boom adds structural rigidity to the collection unit.
The flotation boom 26 has a curved portion 28 which follows the curved end wall 22. A plurality of curved, vertically oriented recesses 30 are provided in the outermost vertical surface of the curved portion 28 and each such recess contains a rotatable resilient bumper roller 32 such that a portion of the outer surface of the roller 32 projects outwardly of its recess. Each roller is mounted on a vertical shaft which in turn is connected to the metal casing at each vertical end as at 34. The rollers 32 serve to buffer any relative movement between the flotation boom 26 and a second air-filled boom 36. The rollers also serve to maintain a space between the booms 26 and 36 so as to avoid damage to the boom 36 which might occur if the two booms were to rub together.
The boom 26 is also provided with a relatively deep well 38 situated in the curved portion 28 and on the longitudinal center line of the unit 12. At the base of the well is one half of a ball-and-socket joint which will be utilized in the towing of the recovery unit 14 behind the collection unit 12 as to be discussed hereinbelow.
The inner wall of the flotation boom 26 mounts bearing means such as a pair of journal or pillow blocks 40, which blocks are mounted on an axis which is perpendicular to the longitudinal axis of the collection unit 12 Each pillow block 40 supports one end of a stub shaft 42, the opposite end of each stub shaft 42 being affixed to a support ring 44 normally situated below the water surface. The ring 44 may thus pivot on the axis of the stub shafts 42.
A central support ring 46 is concentrically located within the support ring 44 and has diametrically opposed mounting bars 48 secured thereto. Each bar 48 is pivotally attached to the outer support ring 44 as at 50 along the longitudinal axis of the collection unit 12 whereby the central support ring is pivotable about the longitudinal axis of the collection unit. Within the central support ring 46 is slidably disposed an elongated sleeve 52. A control yoke 54 is pivoted at its apex 56 to one of the bars 48 and at the opposite end of each leg 58 to the sleeve 52, on an axis parallel to the axis passing through the pillow blocks 40. A cross-bar 60 is secured to the legs 58 adjacent the apex and is attached in a conventional manner to the piston rod of a water impermeable pneumatic cylinder 62 mounted on the bar 48 between the apex 56 and the central ring 46. Actuation of the cylinder 62 will have the effect of pivotting the yoke about its pivot connection to the bar at the apex 56 whereby the sleeve 52 will slidably raise or lower within the central ring 46.
The recovery unit 14 will now be described with reference to the two figures of the drawings. As seen particularly in FIG. 2 a pair of flotation tanks 64 is provided. As with the flotation boom 26 the tanks 64 may be formed of metal and contain a suitable flotation material. Desirably the tank 64 will have a boat-hull-like configuration for good mobility through the water, the tanks being arranged catamaran-style as shown in FIG. 1.
Each tank mounts on its upper surface a journal or pillow block 66 so as to define a transverse axis therebetween. Each block in turn mounts one end of a stub shaft 68 with the opposite end of each stub shaft 68 being secured to a cylindrical holding tank 70. The tank 70 is open at both ends and has an upper portion 72 which projects above the water line W and a lower portion 74 which extends below the water line. The lower portion 74 is provided with an opening 76 the purpose of which will be described hereinbelow.
The upper surface of each tank 64 is provided with hand-rails 78 in a normal fashion and is also provided with a plurality of tie-up cleats 80.
The recovery unit 14 is connected to the collection unit 12 for towing thereby by a catwalk unit 82. The catwalk unit 82 includes a semicircular structure 84 covered by a screen 86 and is also provided with hand-rails 88. As seen in FIG. 1 the structure 84 is elevated with respect to the flotation tanks and a ladder 90 extends between the structure 84 and the top of each flotation tank 64. The catwalk unit is pivotally attached to the flotation tanks at the base of each ladder 90.
At the forward area of the structure 84 a tongue 92 is provided, the tongue being pivotally attached to the upper surface of the structure 84 as at 94. The tongue 92 is wide enough for a person to walk on and is provided with a handrail 96. At the forward end of the tongue 92 a downwardly extending leg 98 fits within the well 38 and has the other half of the ball-and-socket joint secured thereto for mating engagement with the one half already provided at the base of the well 38. Once the joint is secure it is seen that the recovery unit 14 is connected to the collection unit 12 by the catwalk unit 82 and that a degree of freedom between the units 12 and 14 is provided by the ball-and-socket joint and the other pivotal connections, as between the tongue 92 and the structure 84, and between the structure 84 and the flotation tanks 64.
Two further areas of adjustment on the recovery unit are provided. First of all, a stabilizing cable 100 is secured, at one end to the bottom of the holding tank 70. The cable passes over a pulley 102 mounted on the tongue 92 and has its other end secured to a winch 104 mounted on a pedestal 106 atop one of the flotation tanks 64. This mechanism serves two purposes: it maintains the holding tank 70 in a generally vertical orientation during towing and it permits a controlled pivotting of the holding tank 70 on its stub shafts 68 whenever such is desired.
The second adjustment mechanism is provided by the cable 108 which is anchored at one end to one of the flotation tanks 64, passes over a pair of pulleys 110 atop the catwalk structure, and is anchored at the other end to a winch mounted on a pedestal 114 on the other of the flotation tanks. With this mechanism the catwalk unit 82 may be pivotally raised or lowered relative to the recovery unit 14.
The pumping unit 16 will now be described with particular reference to FIG. 1 of the drawings. Below the concentration area C of the collection unit 12 the slidable sleeve 52 is secured to or may be integral with a generally vertical conduit portion 116. Portion 116 continues the sleeve 52 downwardly below the concentration area C and is, of course, slidably vertically adjustable along with the sleeve 52. Contained within the conduit portion 116 is a plurality of similar spiral vanes 118 affixed to the inside wall of the conduit portion 116, which vanes impart a spiral or swirling effect to any fluid passing thereby.
Below the conduit portion 116 is a pumping portion 120 which includes a generally 90° elbow portion 122. Within the pumping portion 120 and between the vanes 118 and the elbow portion 122 is a pump 124 having vanes 126 in the form of propeller blades affixed to a shaft 128. The shaft is maintained coaxial with the conduit and pumping portions 116 and 120 by one or more shaft supports 130. Shaft 128 passes downwardly through a sealed opening 132 in the elbow portion 122 and terminates at a submergible drive motor 134. The motor 134 as well as the height of the sleeve 52 is controlled by an operator situated on the collection unit 12 and provided with appropriate controls 136 mounted thereon. As the necessary circuitry to achieve effective control is well within the expertise of a skilled person in the art it is not considered necessary to discuss the details of such circuitry.
The elbow portion 122 feeds into a rectifier portion 138 which contains vertical and horizontally oriented vanes 140 and 142 respectively. From the rectifier portion 138 a first flexible conduit 144 extends to a sealable joint 146 to which is removably secured a second flexible conduit 148. Conduit 148 extends between the collection unit 12 and the recovery unit 14 and terminates at a second sealable joint 150. Also secured to the second joint 150 is a third length of conduit 152 which in turn sealably feeds into the opening 76 in the lower portion 74 of the holding tank 70. The conduit 152 is oriented relative to the holding tank 70 so that the axis of the conduit 152, and of the conduits 144 and 148 as well, is not aligned with the longitudinal centreline of the units 12 and 14, and hence is not aligned with a radius of the holding tank. This is for the purpose of imparting a circular or spiral motion to fluid exiting from the conduit 52 into the holding tank 70. This effect is further enhanced by an outlet deflector cap 154 which may be secured to the end of the conduit 152 within the holding tank 70, the cap 154 serving to deflect fluid from the conduit 152 towards the inner wall of the holding tank 70.
Operation
The operation of the present invention will now be described, with particular reference to FIG. 1. For such description it is assumed that the complete assembly has been towed, floating on the surface of the water, to an oil spill site by suitable means, as by a tug boat. During such towing operation it is suggested that the length of conduit 148 be disconnected at the joints 146 and 150 to avoid damage and that the holding tank 70 be winched up, as by cable 100, to a generally horizontal attitude to improve the towability of the unit 14 and to avoid damage to the tank.
Once the spill site has been reached the holding tank is lowered so as to assume its generally vertical orientation as shown in FIG. 1 and the conduit 148 is connected at the joints 146, 150. The collection unit is then towed into the spill, connected to a containment boom towed by suitable boats, with the recovery unit being towed by the collection unit. An oil/water mixture is funnelled by the walls 20 into the general vicinity of the collection area C due to the forward movement of the collection unit into the spill. The opening of the sleeve 52 is maintained, under operator control, just below the level of the oil floating on the water surface and the motor 134 is turned on. The motor drives the pump 124 so that an oil/water mixture is drawn downwardly from above the sleeve 52 into the sleeve past the spiral vanes 118. The spiral vanes induce a degree of turbulence into the oil/water mixture, thereby tending to break up the oil from a continuous film or layer into smaller particles which flow more easily past the pump 124 and through the conduits 144, 148 and 152. The rectifier 138 smoothes out the flow of oil/water mixture through the conduits and thus permits some rejoining of the oil particles during the passage through the conduits. The oil/water mixture flows through the conduits 144, 148 and 152 and is deflected by the deflector cap 154 into a flow pattern which is circular and essentially laminar, following the inner wall of the holding tank 70. During such flow within the tank the oil, having a lower specific gravity than the water tends to rise to the surface of the water within the tank. Uncontaminated water will eventually flow out through the open bottom end of the tank.
The tank will eventually contain so much oil that it will, in essence, be full. At that point in time a barge or other vessel could be brought alongside the recovery unit and the oil contained therein could be transferred by conventional means to the barge for appropriate disposal. As an alternative it would be possible to disconnect the full recovery unit from the collection unit, as by disconnecting the ball-and-socket joint and the conduit joint 150 and to connect an empty recovery unit to the collection unit. The full rccovery unit could then be towed to a shore installation for disposal of the oil contained in the full holding tank thereof. Of course, any other suitable method for disposing of oil in the full holding tank could be utilized without departing from the spirit of the present invention.
It is understood, of course, that a skilled person in the art could alter the structure of the described apparatus without departing from the spirit of the present invention. Accordingly the protection to be afforded the invention should be determined from the claims appended hereto. | An oil spill recovery method and apparatus is disclosed. The method of recovery involves the pumping of an oil/water mixture from a concentration area to the submerged portion of a vertically oriented cylinder, open at both ends, and the separation of the oil from the water in the cylinder. Oil floats to and accumulates on the surface of the water in the cylinder and uncontaminated water flows out through the lower open end of the cylinder. The apparatus includes a collection unit which defines the concentration area within three walls thereof, a recovery unit which follows the collection unit and mounts the cylinder therein, and a submerged pumping unit which carries an oil/water mixture from the concentration area in the collection unit to the cylinder in the recovery unit. There is very little emulsification of the oil in the cylinder and hence there is very efficient separation of the oil from the water. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from Japanese Patent Application No. 2010-50361 filed Mar. 8, 2010. The entire content of the priority application is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a coil assembly, and more particularly, to a type thereof including a bobbin having a terminal base, a plurality of terminal electrodes provided at the terminal base, and a plurality of coils wound over the bobbin and each having one end portion and another end portion electrically connected to associated terminal electrodes.
BACKGROUND
A coil assembly such as a transformer includes a bobbin and coils or conductive wires wound over the bobbin. The bobbin has generally cylindrical shape, and a plurality of wires each coated with an electrically insulation layer are wound over an outer peripheral surface of the bobbin. Each wire has a winding portion wound over the bobbin and draw-out portions at each end portion of the wire.
Japanese Patent Application Publication No. H08-111323 discloses a coil assembly in which a terminal base is provided at one axially end portion of a cylindrical portion. The terminal base is provided with a plurality of pin terminals protruding in a direction perpendicular to a circuit board when the coil assembly is surface-mounted on the board. The terminal base is provided with an engaging portion protruding outward so as to engage the draw-out portion of the wire and to direct the draw-out portion toward the pin terminal. Each end portion of the wire is wound over the pin terminal and is electrically connected thereto.
SUMMARY
In such conventional structure, the draw-out portion of the wire is drawn out of the winding portion and is engaged with the engaging portion, and is then drawn to the pin terminal. Therefore, cumbersome production of the coil assembly is required such as engaging the draw-out portion with the engaging portion and winding the draw-out portion over the pin terminal. Further, complicated bobbin structure results.
It is therefore, an object of the present invention to provide a coil assembly having a simplified bobbin structure and capable of facilitating the drawing out work of the draw-out portion toward the pin terminal.
This and other object of the present invention will be attained by a coil assembly to be mounted on a circuit board including a bobbin, at least one electrically conductive wire, first and second pin support portions, and first and second pin terminals. The bobbin is made from an electrically insulating material and includes a wound portion having an end portion, a wire engaging portion, and a terminal base positioned at the end portion. The at least one electrically conductive wire has an electrically insulation coating and includes a winding portion wound over the wound portion and draw-out portions each drawn out from the winding portion and engaged with the wire engaging portion. The first pin support portion and the second pin support portion protrude in a protruding direction from the terminal base. The first pin terminal protrudes in the protruding direction from a free end face of a first pin support portion and is supported thereto. The second pin terminal protrudes in the protruding direction from a free end face of the second pin support portion and is supported thereto. The draw-out portion is electrically connected to associated one of the pin terminals. The pin terminals are configured to extend through the circuit board in the protruding direction which is substantially perpendicular to a surface of the circuit board. The second pin support portion provides a protruding length from the terminal base greater than that of the first pin support portion, and the free end face of the second pin support portion is positioned downstream, in the protruding direction, of an imaginary linear draw-out portion directed linearly from the wire engaging portion to the first pin terminal, such that the second pin support portion is positioned and sized to intersect with the imaginary linear draw-out portion.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a coil assembly according to one embodiment of the present invention;
FIG. 2 is an exploded perspective view of the coil assembly according to the embodiment;
FIG. 3 is a bottom view of the coil assembly according to the embodiment;
FIG. 4 is a front elevational view of the coil assembly according to the embodiment.
FIG. 5 is a front elevational view of a coil assembly according to a first modification to the embodiment; and
FIG. 6 is a front elevational view of a coil assembly according to a second modification to the embodiment.
DETAILED DESCRIPTION
A coil assembly according to a first embodiment of the present invention will be described with reference to FIGS. 1 through 4 . The coil assembly in this embodiment is a transformer including a core 10 , a bobbin 20 , and a conductive wire 50 . Throughout the description, a direction from an upper right portion to a lower left portion in FIG. 1 will be referred to as “+X direction”, a direction opposite to the +X direction will be referred to as “−X direction”, a direction from a lower right portion to an upper left portion will be referred to as “+Y direction”, a direction opposite to the +Y direction will be referred to as “−Y direction”, a direction from the lower portion to the upper portion will be referred to as “+Z direction”, and a direction opposite to the +Z direction will be referred to as “−Z direction”.
As shown in FIG. 2 , a pair of the cores 10 having a shape identical to each other are provided. Each core 10 is E-shaped and includes a bottom plate portion 10 A, a pair of side plate portions 10 B each extending from each end portion of the bottom plate portion 10 A, and a central stem portion 10 C extending from a longitudinally center portion of the bottom plate portion 10 A. Free end faces of the side plate portions 10 B of one of the cores 10 are in contact with free end faces of the side plate portions 10 B of the remaining one of the cores 10 , whereas a free end face of the central stem portion 10 C of one of the cores 10 is spaced apart by a predetermined distance from a free end face of the central stem portion 10 C of the remaining one of the cores 10 .
As shown in FIG. 2 , the bobbin 20 has a sleeve portion 21 having a generally cylindrical shape and made from an electrically insulating resin. The sleeve portion 21 has a generally circular cross-section taken along a plane extending perpendicular to the X direction. The sleeve portion 21 has a cylindrical hollow space into which the central stem portions 10 C of the cores 10 are inserted. The sleeve portion 21 has an axial length of about 18 mm. The sleeve portion 21 corresponds to a wound portion.
A terminal base 31 is provided at one axial end of the sleeve portion 21 , and another terminal base 32 is provided at another axial end of the sleeve portion 21 . The terminal bases 31 , 32 are made from an electrically insulation resin the same as that of the sleeve portion 21 , and are provided integrally with the sleeve portion 21 . Each terminal base 31 , 32 extends in a direction parallel to the Y direction.
As shown in FIG. 3 , the terminal base 31 has a bottom surface 31 Z provided with pin support portions 31 A, 31 B, 31 C, 31 D, 31 E, 31 F, terminal electrodes 31 G, 31 H, 31 I, 31 J, 31 K, 31 L, wire following wall portions 31 M, 31 N, and wire following rectangular protrusions 31 O, 31 P, 31 Q, 31 R, 31 S. Similarly, the terminal base 32 has a bottom surface 32 Z provided with pin support portion 32 A, 32 B, 32 C, 32 D, 32 E, 32 F, terminal electrodes 32 G, 321 J, 32 I, 32 J, 32 K, 32 L, wire following wall portions 32 M, 32 N, and wire following rectangular protrusions 32 O, 32 P, 32 Q, 32 R, 32 S.
The wire following wall portions 31 M, 31 N are positioned at extreme −X end position of the bottom surface 31 Z, and positioned at each end portion of the bottom surface 31 Z in the Y direction. The wire following wall portions 31 M, 31 N are plate shaped extending in Y direction and protruding in −Z direction. A base end portion of each wire following wall portion 31 M, 31 N is provided with a slope portion 31 T, 31 U each having a first region extending in +X direction and a second region extending in Y direction. The slope portions 31 T, 31 U correspond to engaging portions.
Similarly, the wire following wall portions 32 M, 32 N are positioned at extreme +X end position of the bottom surface 32 Z, and positioned at each end portion of the bottom surface 32 Z in the Y direction. The wire following wall portions 32 M, 32 N are plate shaped extending in Y direction and protruding in −Z direction. A base end portion of each wire following wall portion 32 M, 32 N is provided with a slope portion 32 T, 32 U each having a first region extending in +X direction and a second region extending in Y direction. The slope portions 32 T, 32 U correspond to engaging portions.
The wire following rectangular protrusions 31 O through 31 S are positioned between the wire following wall portions 31 M and 31 N and arrayed in Y direction. Neighboring wire following rectangular protrusions are spaced away from each other by a constant predetermined interval. Further, the wire following wall portion 31 is spaced away from the neighboring rectangular protrusion 31 O by the predetermined interval, and wire following wall portion 31 N is spaced away from the neighboring rectangular protrusion 31 S by the predetermined interval. The wire following rectangular protrusions 31 O through 31 S have quadrangular prism shape and extend in −Z direction. These wire following rectangular protrusions 31 O through 31 S correspond to the engaging portions. The same is true with respect to wire following rectangular protrusions 32 O, 32 P, 32 Q, 32 R, 32 S, and geometrical relationship to wire following wall portions 32 M, 32 N.
The pin support portions 31 A through 31 F are provided at extreme +X end portion of the bottom surface 31 Z, and are arrayed in Y direction with a constant interval. Each pin support portion has a cylindrical shape and extends in −Z direction from the bottom surface 31 Z. Each free end portion of each pin support portion is roundish shaped. The pin support portions 32 A through 32 F are provided at extreme −X end portion of the bottom surface 32 Z, and have geometrical relationship and configuration the same as those of the pin support portions 31 A through 31 F.
As shown in FIG. 4 , the pin support portions 31 A, 31 , provided at extreme end portions in the Y direction provide a protruding length from the bottom surface 31 Z smaller than that of the pin support portions 31 B, 31 C, 31 D, 31 E. Further the protruding length of the pin support portions 31 A and 31 F is equal to each other, and protruding length of the pin support portions 31 B, 31 C, 31 D, 31 E is equal to one another. The same is true with respect to the protruding length from the bottom surface 32 Z regarding the pin support portions 32 A through 32 F.
As shown in FIG. 4 , the pin support portion 31 B, 31 E next to the pin support portion 31 A, 31 L provide the protruding length such that an imaginary linear draw-out portion 50 A′ drawn from the slope portions 31 T, 31 U to peripheral surfaces of pin terminals 31 G, 31 L (described later) for winding over the pin terminals 31 G, 31 L can be positioned to overlap with the pin support portion 31 B, 31 E in the Z direction. In other words, a lower end face of the pin support portion 31 B, 31 E is positioned at −Z side with respect to the imaginary linear draw-out portion 50 A′, i.e., the lower end face of the pin support portion 31 B, 31 E is positioned downstream of the imaginary linear draw-out portion 50 ′ in the −Z direction. Stated differently, the imaginary linear draw-out portion 50 A′ is intersected with or crossed with the peripheral surface of the pin support portion 31 B, 31 E as shown in FIG. 3 . The protruding length of the pin support portion 31 A, 31 F is about 1 mm smaller than that of the pin support portions 31 B, 31 , 31 D, 31 E.
The same is true with respect to the pin support portions 32 A through 32 F, the sloped portions 32 T, 32 U, and the imaginary linear draw-out portion 50 A′. In FIG. 4 , the imaginary draw-out portion 50 A′ is coincident with an actual draw-out portion 50 A in the front elevational view.
Terminal electrodes 31 G, 31 H, 31 I, 31 J, 31 K, 31 L in the form of pin terminals protrudes in −Z direction from free end surfaces of the pin support portions 31 A, 31 B, 31 C, 31 D, 31 E, 31 F coaxially therewith. A distance from the bottom surface 31 Z to each free end of each of the terminal electrodes 31 G through 31 L is equal to one another. The same is true with respect to the relationship among terminal electrodes 32 G, 32 H, 32 I, 32 J, 32 K, 32 L, the pin support portions 32 A, 32 B, 32 C, 32 D, 32 E, 32 F, and the bottom surface 32 Z.
Six conductive wires 50 are wound over the bobbin 20 . Each conductive wire 50 includes a copper wire coated with an electrically insulating layer. A first conductive wire 50 is directly wound over the sleeve portion 21 , and an insulating tape is formed over the winding portion. A second conductive wire 50 is wound over the first insulating tape, and then a second insulating tape is formed over the second winding portion. In this way, totally six conductive wires 50 and six insulating tapes including an uppermost tape 80 are alternately provided over the sleeve portion 21 . Each one end portion of each conductive wire 50 is wound over each base end portion of each of the terminal electrodes 31 G through 31 L at a position close to each of the pin support portions 31 A through 31 F and is electrically connected to each terminal electrode by soldering. Similarly, each another end portion of each conductive wire 50 is wound over each base end portion of each of the terminal electrodes 32 G through 32 L at a position close to each of the pin support portions 32 A through 32 F and is electrically connected to each terminal electrode by soldering. Each wire has a first part wound over the sleeve portion 21 as a winding portion, and a second part as draw-out portions 50 A drawn out from the winding portion to the terminal electrode.
More specifically, as shown in FIG. 3 , on the terminal base 31 , draw-out portions 50 A electrically connected to the terminal electrodes 31 G, 31 L are drawn out from the winding portion and are engaged with the slope portions 31 T, 31 U and are contacted with the outer peripheral surfaces of the pin support portions 31 B, 31 E. The draw-out portions 50 A are then wound over the base end portions of the terminal electrodes 31 G, 31 L at a position close to the pin support portions 31 A, 31 F ( FIG. 4 ), and are then electrically connected to the terminal electrodes 31 G, 31 L by soldering.
On the other hand, other draw-out portions 50 A electrically connected to the terminal electrodes 31 H, 31 I, 31 J, 31 K are drawn out from the winding portion and are engaged with the wire following rectangular protrusions 31 O, 31 P, 31 Q, 31 R, 31 S. The draw-out portions 50 A are then wound over the base end portions of the terminal electrodes 31 H, 31 I, 31 J, 31 K at a position close to the pin support portions 31 B, 31 D, 31 C, 31 D, 31 E ( FIG. 4 ), and are then electrically connected to the terminal electrodes 31 H, 31 I, 31 J, 31 K by soldering. The same is true with respect to draw-out portions 50 A on the terminal base 32 .
Soldering of the draw-out portions 50 A to the terminal electrodes is performed by dipping the draw-out portions 50 wound over the terminal electrodes into a molten solder. More specifically, oblique posture of the terminal base 31 is maintained such that lower end faces of the two pin support portions 31 A, 31 B are on an identical horizontal plane parallel to a top surface of the molten solder, and the terminal base 31 is moved downward with maintaining the oblique posture so as to simultaneously dip the end portions of the draw-out portions 50 A on the terminal electrodes 31 G and 31 H. Thus, simultaneous soldering is achieved with respect to these end portions 50 A. The same is true with respect to the end portions of the draw-out portions 50 A in association with the terminal electrodes 31 K and 31 L.
Regarding soldering of the remaining draw-out portions 50 A to the remaining terminal electrodes 31 I, 31 J, these terminal electrodes 31 I, 31 J are moved downward into the molten solder while maintaining their vertical orientation with respect to the surface of the molten solder, so that the end portions of the draw-out portion 50 A in association with the terminal electrodes 13 I, 31 J are subjected to simultaneous soldering. The same is true with respect to the soldering of the draw-out portions to the terminal electrodes 32 G through 32 J. In this way, deposition of surplus solder onto the pin support portions 31 A through 31 F, and 32 A through 32 F can be prevented.
The imaginary linear draw-out portion 50 A′ intersects with the pin support portion 31 B as shown in FIG. 3 , and the protruding length of the pin support portion 31 B from the bottom surface 31 Z of the terminal base 31 is greater than that of the pin support portion 31 A as shown in FIG. 4 . Further, the protruding length of the pin support portion 31 B provides the free end (lower end) of the pin support portion 31 B positioned downstream of the imaginary linear draw-out portion 50 ′ in the −Z direction as shown in FIG. 4 . Accordingly, this pin support portion 31 B can prevent the conductive wire 50 electrically connected to the terminal electrode 31 G from being mechanically interfered with the terminal electrode 31 H.
In the same way, the pin support portions 31 E, 32 B, 32 E can avoid mechanical interference of the draw-out portions 50 A electrically connected to the terminal electrodes 31 L, 32 G, 32 L with the terminal electrodes 31 K, 32 H, 32 K.
Various modifications are conceivable. For example, in the above-described embodiment, each draw-out portion 50 A is wound at each base portion of each terminal electrode at a position near each pin support portion. However, each draw-out portion or one of the draw-out portions can be wound at a portion other than the base end portion, for example, near the free end portion of each terminal electrode.
More specifically, as shown in FIG. 5 , in a coil assembly 1 A shown in FIG. 5 , the rightmost draw-out portion 50 A is wound over the first pin terminal 31 G and electrically connected thereto at a position remote from the free end face of the first pin support portion 31 A and positioned downstream, in the protruding direction (in the direction), of the free end face of the second pin support portion 31 B. The same is applied to the draw-out portion 50 A connected to the pin terminal 31 L.
With this arrangement, each free end portion of each terminal electrode can be simultaneously dipped into the molten solder while maintaining vertical orientation of terminal electrodes with respect to the surface of the molten solder for simultaneous soldering the all draw-out portions to the all terminal electrodes.
Further, in the above-described embodiment, protruding length of the pin support portion 31 B, 31 E (or 32 B, 32 E) is equal to that of the pin support portion 31 C, 31 D (or 32 C, 32 D). However, the protruding length of the pin support portion 31 B, 31 E ( 32 B, 32 E) can be different from that of the pin support portion 31 C, 31 D ( 32 C, 32 D). For example, in a coil assembly 1 B shown in FIG. 6 , regarding pin support portion 31 B, 31 C′ protruding length of the most upstream side pin support portion 31 C′ can be greater than that of the pin support portion 31 B positioned immediate downstream of the pin support portion 31 C′ in the −Y direction. The same is true with respect to the pin support portions 31 D′, 31 E. Protruding length of the most upstream side pin support portion 31 D′ can be greater than that of the pin support portion 31 E positioned immediate downstream of the pin support portion 31 D′ in the +Y direction. Thus, mechanical interference of the draw-out portions 50 A electrically connected to the terminal electrodes 31 H, 31 K with the terminal electrodes 31 I, 31 J can be prevented by the elongated pin support portions 31 C′ and 31 D′.
Further, the number of the conductive wires and the terminal electrodes and shape of the bobbin and the core are not limited to the above-described embodiment. Furthermore, the coil assembly is not limited to the transformer.
While the invention has been described in detail with reference to the specific embodiment thereof, it would be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention. | A coil assembly having a simplified bobbin structure and facilitating connection of a draw-out portion of a wire to a pin terminal. A coil assembly includes first and second pin support portions protruding in a protruding direction from a terminal base. First and second pin terminals protrude in the protruding direction from free end faces of the first and second pin support portions, respectively. The draw-out portion is electrically connected to an associated one of the pin terminals. The second pin support portion provides a protruding length from the terminal base greater than that of the first pin support portion, and the free end face of the second pin support portion is positioned downstream, in the protruding direction, of an imaginary linear draw-out portion directed linearly from the wire engaging portion to the first pin terminal, such that the second pin support portion is positioned and sized to intersect with the imaginary linear draw-out portion. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a spool type direction control valve for controlling the flow direction of an hydraulic circuit and, more particularly, to a direction control valve fitted with a flow control mechanism.
A variety of direction control valves of this type have been used thus far in the art. Typical of these is the construction disclosed in Japanese Patent Publication No. 49-21693.
FIG. 1 shows a direction control valve of the spool translation type which is used for controlling the flow of the pressure oil into and from a tilting cylinder for a forklift truck.
In the operation of the direction control valve, when a spool member 31 is displaced towards the left in FIG. 1, a plunger 33 is shifted towards the left by the pressure prevailing in an oil supply port 32 and against the force of a spring 34 so as to establish hydraulic communication between grooves 35 and 36 so that the pressure fluid from the supply port 32 is conveyed from the supply port 32 through these grooves 35 and 36 and a connecting pipe 37 to the head side oil chamber 38a in the tilting cylinder 38. On the other hand, since the displacement of the plunger 33 puts the grooves 39 and 40 into communication with each other, the pressure fluid in the rod side oil chamber 38b to a tank port 42 through a connecting pipe 41 and the grooves 39, 40, so that the mast is tilted forwards. Conversely, when the spool member 31 is displaced towards the right, the pressure oil from the supply port 32 causes a check valve 43 to open so that it may flow from the groove 40 into the groove 39 such that the pressure oil is supplied through the connecting pipe 41 into the rod side oil chamber in the tilting cylinder 38. At this time, a small plunger 44 is shifted towards the right in FIG. 1 by the fluid pressure prevailing in the supply side, against the force of a spring 45, so as to establish hydraulic communication between the grooves 35 and 36 through a groove 46 formed in the small plunger 44 so that the pressure fluid in the head side oil chamber in the tilting cylinder 38 flows into the tank port 47 through the connecting pipe 37 and grooves 36, 35 for tilting the mast rearwards.
The above described direction control valve shown in FIG. 1 has a defect in that it is highly complicated in structure. In addition, since the sectional area of the pressure oil passage during mast tilting is dictated by the plunger position controlled in turn by the spring and the pilot pressure of the supply side pressure fluid, the speed of forward tilting during such forward mast tilting is changed as a function of the load acting in the forward tilting direction, even granting that the pressure fluid in the rod side oil chamber of the tilting cylinder is discharged via throttling means. Also, since the passage is opened and closed by plunger operation, the pressure fluid cannot but leak under the shut-off state with the spool in the neutral position. Thus there is an additional defect in that the mast, which is subject at all times to the load acting in the forward tilt direction, can not be maintained for a prolonged time at a fixed position.
SUMMARY OF THE INVENTION
It is therefore a principal object of the present invention to overcome the aforementioned problems inherent in prior direction control valves fitted with a flow control mechanism.
For accomplishing the object, the present invention provides a direction control valve in which the flow direction towards a hydraulic cylinder of the pressure fluid introduced from a pressure source into a valve body is controlled by the switching operation of a spool member, wherein, according to the invention, there is provided, in a passage connecting one of the oil chambers of the hydraulic cylinder to the spool member, a flow control mechanism consisting essentially of a poppet type piston adapted for opening and closing the passage. When the spool member is switched over for supplying the pressure fluid to the other oil chamber of the hydraulic cylinder, the pilot pressure from the pressure source is caused to act on said poppet type piston in the valve opening direction, while the back pressure of the discharge side pressure fluid corresponding to the load acting on the one oil chamber of the hydraulic cylinder is caused to act on the piston in the valve closing direction, in a manner to control the flow of the pressure fluid from the one oil chamber of the hydraulic cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing a prior-art direction control valve.
FIG. 2 is a sectional view showing the direction control valve according to a first embodiment of the present invention.
FIG. 3 is a sectional view showing the direction control valve according to a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is made to FIG. 2 illustrating a direction control valve fitted with a flow control mechanism according to a first embodiment of the present invention. In the drawing, the numeral 1 designates a valve body in which there are incorporated a flow control unit 5 made up of a first piston 2, a second piston 3 and a spring 4, and a translation or direct acting type spool member 14. The first piston 2 at the left side in FIG. 2 has an integral structure comprised of a left-hand side piston portion 2a slidable within a first pressure chamber 6, a right-hand side poppet portion 2b slidable within a second pressure chamber 7, and a rod 2c coaxially connecting the piston and poppet portions 2a and 2b to each other. The poppet portion 2b is adapted to seat on or be separated from a seat 11 formed on a circular passage 10 adapted for providing hydraulic communication between a first port 8 and a second port 9. It will be noted that an orifice 12 is formed in the poppet portion 2b for providing hydraulic communication between the second port 9 and the second pressure chamber 7. The first port 8 communicates with an operating port in a spool member 14 through an oil passage 15 formed in the valve body 1, while the second port 9 communicates via oil passage 18A with a rod side oil chamber 17a in the tilting cylinder 17 adapted for tilting the mast 16 in the forklift truck. A head side oil chamber 17b in the tilting cylinder 17 communicates via an oil passage 18B with another operating port in the spool member 14.
The second piston 3 at the right-hand side in FIG. 2 is made up of a piston portion 3a slidable within a third pressure chamber 13 and a rod portion 3b abutting on an end face of the poppet portion 2b of the first piston 2 and is urged towards the first piston 2 by the spring 4 disposed within the third pressure chamber 13.
The pressure chambers 6, 7 and 13 in the above described flow control unit 5 are subject to pilot pressures derived from different oil systems. Thus a pilot pressure from a hydraulic pump P is introduced into the first oil chamber 6 by way of a pilot line 19 for thrusting the piston portion 2a of the first piston 2 towards the right, while a pilot pressure derived from the rod side oil chamber of the tilting cylinder 17 is introduced via pilot line 18A and orifice 12 into the second pressure chamber 7 for thrusting the poppet portion 2b of the first piston 2 towards the left. On the other hand, the pilot pressure derived from the hydraulic pump P and conveyed through the spool member 14 or the back pressure of the pressure fluid discharged from the rod side oil chamber 17a when the tilting cylinder 17 is tilted forwards is introduced into the third pressure chamber 13 via pilot line 20 for thrusting the piston portion 3a of the second piston 3 towards the left. The spool member 14 is provided with a throttle 21 for limiting the flow of the pressure fluid discharged from the rod side oil chamber 17a when the tilting cylinder 17 is tilted forwards. In the neutral position, the pump and tank ports are communicated with each other.
The above described direction control valve of the first embodiment operates as follows:
(When Hydraulic Pump P is Halted)
Since a low pilot pressure prevails in both the first pressure chamber 6 and the third pressure chamber 13, the first piston 2 is subject to a leftwards acting force in FIG. 2 by the spring 4 acting on the second piston 3 and the pilot pressure from the rod side oil chamber 17a of the tilting cylinder 17 acting on the second pressure chamber 7, it being understood that the load acts at all times on the rod-side oil chamber due to the weight of the associated material handling device, whereby said circular passage 10 is closed by said poppet portion 2b being contacted with said seat 11. In this case, however, the pilot pressure acts to the right on the taper surface of the poppet portion 2b of the first piston 2 so that a pressure corresponding to the differential area between the right-hand end pressure-receiving surface and the tapered pressure-receiving surface of the poppet portion 2b acts to urge the poppet portion 2b leftwards. Therefore, the poppet portion 2b is made to seat with the seat 11 with the combined force of the pressure of the spring 4 and the pilot pressure equivalent to the differential pressure receiving area.
(Forward Mast Tilting)
When the spool member 14 is switched over to forward tilting (a), the pressure fluid from the hydraulic pump P is supplied via oil passage 18B into head-side oil chamber 17b of the tilting cylinder 17. At this time, the pilot pressure from the hydraulic pump P is larger than the combined force of the pressure of the spring 4 and the pilot pressure in the second pressure chamber 7 and acts on the first pressure chamber 6 to cause the first piston 2 to be shifted towards the right. As a result, the poppet portion 2b of the first piston 2 is displaced from the seat 11 to open the oil passage 10. Thus a limited amount of the pressure fluid contained in the rod side oil chamber 17a of the tilting cylinder 17 is discharged into the tank by way of the oil passage 18A, second port 9, oil passage 10, first port 8, oil passage 15 and the throttle 21 of the spool member 14.
In this manner, the tilting cylinder 17 is actuated in a direction for extending the piston rod thereof for tilting the mast 16 forward. In this case, when the first piston 2 is moved rightwards, the force of the spring 4 increases, while the back pressure of the pressure fluid discharged from the rod side oil chamber 17a of the tilting cylinder 17 acts on the third pressure chamber 13 via the line 20, so that the force thrusting the first piston 2 towards the left increases. As a result thereof, the first piston 2 is stabilized at a position where the combined force of the spring pressure and the back pressure is counterbalanced by the pilot pressure prevailing in the first pressure chamber 6. Thus the poppet portion 2b that determines the opening degree of the oil passage 10 assumes a position corresponding to the value of the back pressure exerted by the pressure fluid at the discharge side of the tilting cylinder 17, i.e. the magnitude of the load acting on the material handling device. Thus the greater the magnitude of the load, the lesser the opening degree of the oil passage 10 and the discharge flow from the tilting cylinder 17 become.
(Rearward Mast Tilting)
When the spool member 14 is switched to rearward tilting (b), the pilot pressure from the hydraulic pump P acts on the first pressure chamber 6 through a pilot line 19, while also acting on the third pressure chamber 13 through a pilot line 20. On the other hand, the pressure fluid from the pump P acts directly on the tapered surface of the poppet portion 2b via the first port 8 and oil passage 10. Thus, as the force for displacing the first piston 2 towards the right, pump pressure acts on the tapered surface of the poppet portion 2b and the first pressure chamber 6. This force is counteracted by the force combined from the pressure of the spring 4, the pilot pressure at the rod side of the tilting cylinder 17 acting on the second pressure chamber 7 and the pilot pressure of the hydraulic pump P acting on the third pressure chamber 13.
In this manner, the poppet portion 2b may be separated from the seat 11 for opening the oil passage 10 by setting the pressure receiving area of the first piston 2 and that of the second piston 3 such that the force for thrusting the first piston 2 towards the right will be in excess of that towards the left. In this manner, the pressure fluid from the pump P is supplied via second port 9 and oil passage 18A to the rod side oil chamber 17a of the tilting cylinder 17 for retracting the piston rod for tilting the mast rearwards.
(Neutral Position)
When the spool member 14 is switched to its neutral position as shown, the hydraulic pump P is communicated with the tank and the pressure in the first pressure chamber 6 is lowered. Thus the first piston 2 is shifted towards the left under the force of the spring 4 and the pressure from the rod-side oil chamber 17a of the tilting cylinder 17 acting on the second pressure chamber 7, so that the poppet portion 2b is brought to seat with the seat 11 to thereby seal the passage 10.
The second embodiment of the present invention will be explained by referring to FIG. 3. In the present second embodiment, the so-called double piston type flow control unit according to the preceding embodiment of FIG. 2 is replaced by a single piston type unit. In the present embodiment, the pilot pressure of the hydraulic pump P is introduced into the first pressure chamber 6 in which the piston portion 2a of the piston 2 is engaged, while the back pressure of the discharged fluid from the rod side oil chamber 17a of the tilting cylinder 17 is introduced into the second pressure chamber 7 in which the poppet portion 2b is engaged. However, the force of the spring 4 is selected to be stronger than that for the first embodiment and is also selected to be sufficient enough to overcome the pressure from the rod side oil chamber 17a of the tilting cylinder 17 acting on the tapered surface of the poppet portion 2b.
Thus, in the neutral state of the spool member 14 or when the hydraulic pump P is at a standstill, the poppet portion 2b is seated with the seat 11 to seal the oil passage 10 for holding the tilting cylinder at a standstill state.
When the spool member 14 is switched to forward tilting (a), the pressure fluid from the hydraulic pump P is supplied to the head side oil chamber 17b of the tilting cylinder 17, while the pilot pressure of the hydraulic pump P acting on the first pressure chamber 6 acts to shift the piston 2 rightwards, the poppet portion 2b then opening the oil passage 10 and the pressure fluid in the rod-side oil chamber 17a of the tilting cylinder 17 being returned to the tank via the line 18A, port 9, passage 10, port 8, line 15 and throttle 21. In this case, the back pressure of the pressure fluid at the discharge side of the tilting cylinder 17 is also introduced into the second pressure chamber 7 via line 20 for acting as a force thrusting the piston 2 leftwards as in the first embodiment described above. As a result, the degree of opening of the passage by the poppet portion 2b is linearly correlated with the magnitude of the back pressure corresponding to the load acting on the tilting cylinder 17. Thus the tilting cylinder 17 acts to tilt the mast 16 forwards at a controlled speed which is linearly correlated with load magnitude.
When the spool member 14 is switched to rearward tilting (b), the pilot pressure from the hydraulic pump P acts separately on the first pressure chamber 6 and the second pressure chamber 7, while the pressure fluid from the pump P acts on the tapered surface of the poppet portion 2b, so that the piston 2 is shifted towards the right for opening the oil passage 10. Thus the pressure fluid from the hydraulic pump P is supplied to the rod-side oil chamber 17a of the tilting cylinder 17, while that in the head side oil chamber 17b is returned into the tank T via line 18B, the tilting cylinder 17 tilting the mast 16 rearwards.
From the foregoing it will be seen that the present invention provides a direction control valve fitted with a flow control mechanism which is highly simplified in structure and in which pressure fluid leakage is almost nil when the pressure fluid is shut-off, so that the tilting cylinder can be accurately maintained at the position at which it halted, whereas, with the mast tilted forwards, the speed of forward tilting can be controlled in relation to the magnitude of the load acting on said mast in the direction of forward tilting. | There is disclosed a spool type direction control valve for controlling the oil flow direction in a hydraulic circuit including a pressure source, a hydraulic cylinder and a spool member. A flow control mechanism is provided in an oil passage connecting one of the oil chambers of the hydraulic cylinder to the spool member. The flow control mechanism comprises a poppet type piston adapted for opening and closing the oil passage. When the spool member is switched over for supplying the pressure fluid to the other oil chamber of the hydraulic cylinder, the pilot pressure from the pressure source is caused to act on the piston in the valve opening direction, while the back pressure of the discharge side pressure fluid corresponding to the load acting on the one oil chamber is caused to act on the piston in the valve closing direction, so as to control the discharge flow of the pressure fluid from the one oil chamber. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cassette for containing a magnetic tape cassette to be used preferably for a video tape cassette, and more particularly to such a cassette capable of preventing engagement members of a reel locking device from being deteriorated to make it possible to certainly lock reels, and also capable of decreasing the number of parts constituting the reel locking device.
2. Description of the Related Art
FIG. 1 illustrates an inside structure of a conventional cassette for containing a magnetic tape (hereinafter, referred to as "magnetic tape cassette). A video tape cassette 5 comprises a cassette half 51 (an upper cassette half is removed for clarity, and hence only a lower cassette half is illustrated in FIG. 1) in which a pair of reels 52 and 53 are disposed for rotation. Around each of the reels 52 and 53 is wound a magnetic tape 54. The magnetic tape 54 is guided by tape guides 55 and 56 disposed in the vicinity of a front (an upper side in FIG. 1) and at opposite sides of the cassette 5 so that the magnetic tape 54 passes along an opening 57 formed in the vicinity of the front of the cassette half 51. The reels 52 and 53 are formed with lower flanges 58, 59 which are formed at a whole perimeter thereof with teeth 60 and 61, respectively.
There is disposed a lock member 62 which is disposed in an almost triangular space located in the vicinity of a rear of the cassette 5 and between the pair of the reels 52 and 53, and which acts as a reel locking device for preventing the reels 52 and 53 from rotating in order not to loosen the wound magnetic tape 54 in transportation and handling thereof while the video tape cassette 5 is not being loaded in a video deck (not illustrated).
The conventional lock member 62 is formed with almost triangular shaped ribs 80 and 81 between a rear plate 63 of the cassette half 51 and the pair of reels 52, 53. The ribs 80 and 81 have straight portions 65 and 66 extending in a front-rear direction of the cassette half and parallel to each other, and an engagement member 67 is slidably interposed between the straight portions 65 and 66. A compressed spring 68 disposed between the rear plate 63 and the engagement member 67 exerts pushing force on the engagement member 67 towards the front of the cassette half. The engagement member 67 is formed at a bottom surface thereof with an opening 69 through which a lock-releasing pin of a video deck is to be inserted. The cassette half 51 is formed at a bottom surface 70 thereof with an opening (not illustrated) located in alignment with the opening 69 of the engagement member 67.
The engagement member 67 is suitably made of elastic resin, and has a rectangular-shaped slide body 71 having a relatively wide bottom surface area for stable slide movement, as illustrated in FIG. 2. The slide body 71 is integrally formed at a front end surface thereof with a pair of engagement claws 72 and 73 which are engagable to the teeth 60 and 61 formed with the reels 52 and 53, respectively.
The engagement claws 72 and 73 are designed to be relatively long and to have thin hinge portions 74 and 75, respectively, at the proximal ends of the engagement claws 72 and 73, that is, at joint portions connecting the engagement claws 72 and 73 to the slide body 71. Thus, the engagement claws 72 and 73 are able to elastically and transversely swing as shown with arrows A in FIG. 2. As illustrated in FIG. 2, a guide member such as pins 90 are disposed on the cassette half 51 in a projecting fashion. The pins 90 ensure that the engagement claws 72 and 73 open relative to each other to engage to the teeth 60 and 61 for locking the reels 52 and 53 as the slide body 71 makes slide movement towards the front of the cassette half, and that the engagement claws 72 and 73 close relative to each other or move towards each other to move away from the teeth 60 and 61 for releasing lock of the reels as the slide body 71 makes slide movement towards the rear of the cassette half. The magnetic tape cassette having the reel locking device as mentioned above is suggested, for instance, in Unexamined Japanese Patent Publication No. 7-14342.
On the other hand, there has been suggested another magnetic tape cassette 8 as illustrated in FIG. 3 in which engagement portions 200 and 201 are prepared separately from a slide body 202, and are secured to a cassette half 83 for rotation. The engagement portions 200 and 201 are maintained to be pushed towards the reels 85 and 86 by a spring 84. For instance, refer to Unexamined Japanese Patent Publication No. 6-44733.
When the video tape cassette 8 is not being loaded into a video deck, the slide body 202, which is designed to be slidable by a suitable guide member in a front-rear direction of the cassette, is pushed by a compressed spring 87 to the foremost movement location. In this stage, the engagement claws 88 and 89 are guided to insert into the adjacent teeth 95 and 96, respectively, so that the reels 85 and 86 are surely locked.
When the video tape cassette 8 is loaded into a video deck, the slide body 202 retreats with the result that engagement members 92 and 93 of the engagement portions 200 and 201 are pushed by the slide body 202 towards the rear of the cassette. Thus, the engagement portions 200 and 201 are made to rotate in clockwise and counterclockwise directions, respectively, and hence the engagement claws 88 and 89 are made to come out of engagement with the teeth 95 and 96, resulting in that lock of the reels 85 and 86 are released.
In the former video tape cassette 5, the engagement claws 72 and 73 are designed to be elongated and to have the hinge portions 74 and 75 by forming the proximal ends of the engagement claws 72 and 73 to be thin so that the engagement claws 72 and 73 of the engagement member 67 of the lock member 62 are transversely swingable. Thus, the hinges 74 and 75 are often fatigued when the video tape cassette 5 falls on a floor or by long term use, for instance, so that the engagement claws 72 and 73 would be broken at the hinge portions 74 and 75 or would be deformed plastically with the result of uncertain lock of the reels 52 and 53.
On the other hand, in the latter video tape cassette 8, the magnetic tape cassette has to have a greater number of parts since the engagement portions are formed separately from the slide body, and the spring 84 has to be prepared for urging the engagement portions 200 and 201 toward the reels. In addition, the video tape cassette 8 has much complexity in assembling thereof. In particular, each of parts has to be small in a small-sized magnetic tape cassette. Thus, if there are a great number of parts, the assembling of the cassette unpreferably takes too much time and labor. The above mentioned problem also arises in various types of magnetic tape cassettes as well as the video tape cassettes 5 and 8.
SUMMARY OF THE INVENTION
In view of problems of conventional magnetic tape cassettes, the present invention has an object to provide a magnetic tape cassette capable of surely locking reels, ensuring stable lock of reels even in long term use, decreasing the number of assembly parts, and being readily assembled.
The present invention provides a cassette for magnetic tape which includes a pair of cassette halves cooperating with each other to form a cassette body; a pair of reels disposed rotatably in one of the cassette halves to wind a magnetic tape around the respective reels, each of the reels including a flange having a plurality of teeth formed at its circumference; and a reel locking assembly engaging the flange for preventing rotation of the reels, in which the reel locking assembly includes: a slide body disposed between the reels slidably in a front-rear direction of the cassette body; an urging member urging the slide body towards a front of the cassette body; a support member disposed near left and right sides of the slide body; and a lock-engagement member having a central portion which is supported rotatably by the support member along a plane of the cassette body, the lock-engagement member being made of metal having resiliency. The lock-engagement member further includes a first engagement end engaged to the slide body and a second engagement end which is enabled to engage the teeth of the flange with the slide body being positioned at its foremost movement position.
In a preferred embodiment, the slide body is formed with an elongated hole extending in a slide direction thereof, the one of engagement ends being to be inserted into the elongated hole for slide movement so as to delay starting rotation of the lock-engagement members on retreat movement of the slide body.
In another preferred embodiment, each of the lock-engagement members is wound at least once at a central portion thereof like a coil to form a hole, and each of the supporters comprise a shaft which is to be inserted into the hole.
In still another preferred embodiment, the engagement ends of the lock-engagement members have the same configuration.
In a cassette for magnetic tape provided in accordance with the present invention, the slide body is urged toward the reels by an urging member when the magnetic tape cassette is not being loaded in a cassette deck. One of the engagement ends of the lock-engagement members rotatably disposed in the cassette half is pushed forwardly by the slide body, and thus the other of the engagement ends is made to be inserted into the teeth of the reels, so that the reels are locked. Since the lock-engagement members are made of metal having resiliency, it is possible to prevent the engagement ends from being fatigued or deteriorated while ensuring lock of the reels. In addition, since the engagement members have resiliency, it is no longer necessary to prepare a spring for urging the engagement members toward the reels, so that the number of parts are decreased.
When the magnetic tape cassette is loaded in a cassette deck, the slide body is pushed by a lock releasing pin of the cassette deck to retreat, and thus the lock-engagement members rotate in a direction away from the reels. Thus, the other of the engagement ends of the lock-engagement members are made to come out of engagement with the teeth of the reels, so that the lock of the reels is released.
The slide body has an elongated hole extending in a front-rear direction of the cassette, in which hole is to be engaged one of the engagement members of the lock-engagement members. Thus, when the engagement ends slide in the elongated hole and thus the slide body retreats by a certain distance, the lock-engagement members start to rotate. Accordingly, when a certain period of time passes after the magnetic tape cassette has been loaded in a cassette deck, the lock of the reels is released, which can prevent the magnetic tape from being loosened while the magnetic tape is being loaded.
By designing the engagement ends of the lock-engagement members to be the same in shape, it is no longer necessary to pay attention with respect to upper or lower side and left or right side of the lock-engagement members, when the lock-engagement members are inserted into shafts of the cassette half. Thus, it is possible to decrease the number of assembly parts, and also possible to easily assemble. In addition, by winding the lock-engagement members at least once at a central portion thereof like a coil to form a hole, it is possible to maintain the resiliency to be high even if the lock-engagement members are small in size.
The above and other objects and advantageous features of the present invention will be made apparent from the following description made with reference to the accompanying drawings, in which like reference characters designate the same or similar parts throughout the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a conventional video tape cassette with an upper cassette half thereof being removed for clarity;
FIG. 2 is an enlarged view of a part of the video tape cassette illustrated in FIG. 1;
FIG. 3 is an enlarged view of a part of another conventional video tape cassette;
FIG. 4 is a plan view of a part of a video tape cassette to which a magnetic tape cassette made in accordance with the present invention is applied;
FIG. 5 is a perspective view of a slide body;
FIG. 6 is a cross-sectional view taken along the line VI--VI in FIG. 5;
FIG. 7 is a cross-sectional view taken along the line VII--VII in FIG. 5;
FIGS. 8A and 8B are perspective views of lock-engagement members; and
FIG. 9 is a perspective view of a lock member positioned in place with certain parts omitted for the sake of clarity.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 4 to 9, hereinbelow will be described a preferred embodiment in which a magnetic tape cassette made in accordance with the present invention is applied to a video tape cassette.
As illustrated in FIG. 4, a video tape cassette 1 made in accordance with the invention comprises a cassette half 11 (an upper cassette half is removed for the sake of clarity, and hence only a lower cassette half is illustrated in FIG. 4) in which a pair of reels 12 and 13 are disposed for rotational movement. Around each of the reels 12 and 13 is wound a magnetic tape (not illustrated). The reels 12 and 13 each have lower flanges with teeth around their entire perimeter, 18 and 19, respectively.
There is disposed a lock member 21 which is disposed in an almost triangular space 20 located in the vicinity of a rear of the video tape cassette 1 and between the pair of the reels 12 and 13, and which acts as a reel locking device for preventing the reels 12 and 13 from rotating in order not to loosen the wound magnetic tape while the video tape cassette 5 is not being loaded in a video deck (not illustrated). Parts other than the lock member 21 have the same function as those of the conventional video tape cassette 5 having been described with reference to FIG. 1, and hence explanation about them is omitted.
The lock member 21 comprises a slide body 22 disposed for slide movement between the pair of the reels 12 and 13, a compressed spring 23 for urging the slide body 22 towards the reels 12 and 13, and lock-engagement members 40 and 41 disposed at the either side of the slide body 22. As illustrated in FIG. 5, the slide body 22 is formed with a hollow portion 24 into which a lock releasing pin is to be inserted, and further with a guide portion 25 at the rear of the hollow portion 24. As illustrated in FIG. 6, the hollow portion 24 is shaped in a relatively deep dome. There is formed an inclined surface 27 at a bottom of an opening 26 at a rear end of the hollow portion. The hollow portion 24 has a relatively small width so that it can enter a space present between the pair of the reels 12 and 13.
As later explained, when the video tape cassette 1 is loaded in a video deck, a lock releasing pin (not illustrated) of a video deck pushes the inclined surface 27 to thereby cause the slide body 22 to retreat, so that the reels 12 and 13 are released from being locked. The hollow portion 24 is designed to have a length so that the lock releasing pin does not abut a front end of the slide body when the slide body 22 retreats by a certain distance, namely until the reels 12 and 13 are released from being locked. There is formed a guide groove 28 having a predetermined width at the center of a front wall of the hollow portion 24.
As illustrated in FIG. 5, the guide portion 25 is formed a U-shaped recess 29 which is open upwardly for containing an end of the compressed spring 23. Wholly along an inner surface of the U-shaped recess 29 is formed a projecting rib 30. Adjacent to the projecting rib 30 is formed an engagement groove 31 into which an end of the compressed spring 23 is to be fixed.
The guide portion 25 is formed at an upper surface thereof with engagement holes 42 and 43 to which one of the engagement ends of the lock-engagement members 40 and 41 are inserted. The engagement holes 42 and 43 are designed to be elongated holes extending in a direction in which the slide body 22 makes slide movement. As illustrated in FIGS. 5 and 7, the guide portion 25 is formed at a bottom surface and at opposite sides thereof with guide grooves 32 and 33. The guide grooves 32 and 33 are to be fit into guide rails 34 and 35 formed on the cassette half 11, respectively, so that the slide body 22 slides linearly only in a front-rear direction of the cassette.
As illustrated in FIGS. 8A and 8B, the lock-engagement members 40 and 41 are made of spring wire rod composed of metal having certain resiliency such as SUS 304, and include coil portions 44 and 45, respectively. Opposite ends of the coil portions 44 and 45 are inwardly bent to define engagement ends 46, 47, 48 and 49. The upper engagement ends 46 and 48 are L-shaped. The lock-engagement members 40 and 41 are formed with bending portions 471 and 491 (see FIG. 4) between the lower engagement ends 47, 49 and the coil portions 44, 45 for facilitating insertion of the lower engagement ends 47, 49 into the teeth 18, 19.
The spring wire rod constituting the lock-engagement members has a diameter in the range of 0.2 mm to 0.8 mm, preferable in the range of 0.3 mm to 0.6 mm. The number of winding the spring wire rod in the coil portions 44 and 45 is at least one, preferably in the range of 4 to 20, and more preferably in the range of 8 to 18.
When a relatively thick spring wire rod (for instance, a rod having a diameter of 0.8 mm) is to be used, if an interval between the adjacent teeth of the reels is smaller (for instance, 0.5 mm) than the diameter of the spring wire rod, the engagement ends 47 and 49 are formed to be flat.
As illustrated in FIG. 4, there are disposed standing shafts 100 and 101 as a support member in the vicinity of the guide rails 34 and 35. The coil portions 44 and 45 of the lock-engagement members 40 and 41 are placed over the shafts 100 and 101, respectively. The upper engagement ends 46 and 48 are engaged to the elongated holes 42 and 43 of the slide body 22, respectively so that the upper engagement ends 46 and 48 are able to move by a certain distance. In front of the standing shafts 100 and 101 stand stopper pins 102 and 103 which restricts movement of the lower engagement ends 47 and 49 of the lock-engagement members 40 and 41.
As best shown in FIG. 9, the cassette half 11 is formed with a square pole shaped stopper 104 for restricting advance movement of the slide body 22. The lower engagement ends 47 and 49 of the lock-engagement members 40 and 41 are inserted between the teeth 18 and 19 of the reels by more than a certain distance with the slide body 22 being kept in abutment with the stopper 104, so that the reels 12 and 13 are surely locked. There is formed a linear-shaped guide projection 105 at the rear of the stopper 104.
The guide projection 105 is inserted into the guide recess 28 formed at the hollow portion 24 of the slide body 22. Thus, a front end of the hollow portion 24 is able to linearly move. In addition, there is formed a pin insertion opening 106 at the rear of the guide projection 105 in alignment with the hollow portion 24 of the slide body 22. A lock releasing pin of a video deck is to be inserted into the hollow portion 24 of the slide body 22 through the pin insertion opening 106.
With reference to FIG. 4, hereinbelow will be explained the operation of the lock member 21. Since a lock releasing pin of a video deck is not inserted into the hollow portion 24 of the slide body 26 when the video tape cassette 1 is being taken out of the video deck, the slide body 22 is compressed to the stopper 104 disposed in front thereof by a pushing force exerted by the compressed spring 23.
In this situation, the lower engagement ends 47 and 49 of the lock-engagement members 40 and 41 are being inserted between the adjacent teeth 18 and 19 of the reels 12 and 13, so that the reels 12 and 13 are surely locked. Thus, the magnetic tape is prevented from being loosened, and it is possible to prevent the magnetic tape from getting twisted around a guide roller of the video deck when the video tape cassette 1 is loaded into the video deck. Furthermore, since the lower engagement ends 47 and 49 are restricted in position by the stopper pins 102 and 103, it is possible to avoid unusual deformation of the lower engagement ends 47 and 49, even if the slide body 22 makes further advance movement.
When the video tape cassette 1 is loaded into the video deck, a lock releasing pin (not illustrated) of the video deck enters the opening 26 of the hollow portion 24 through the pin insertion opening 106 of the cassette half 11. Thus, the lock releasing pin of the video deck pushes the inclined surface 27 (see FIG. 6), causing the slide body 22 to retreat by a certain distance against the pushing force exerted by the compressed spring 23. Thus, the lower engagement ends 47 and 49 of the lock-engagement members 40 and 41 are entirely drawn out from the teeth 18 and 19 of the reels 12 and 13, respectively, as shown with two-dot chain lines in FIG. 4. Thus, the reels 12 and 13 are released from being locked, and hence now rotatable.
Herein, the upper engagement ends 46 and 48 of the lock-engagement members 40 and 41 are engaged in the elongated holes 42 and 43 formed on the slide body 22 so that the upper engagement ends 46 and 48 are slidable in a direction in which the slide body makes sliding movement, the lock-engagement members 40 and 41 start to rotate after the slide body 22 has retreated by a certain distance.
Accordingly, when a certain period of time passes after the magnetic tape cassette 1 has been loaded in a cassette deck, the reels are released from being locked, which can prevent the magnetic tape from being loosened while the magnetic tape is being loaded.
As mentioned earlier, since the lock-engagement members 40 and 41 are made of metal having resiliency, it is possible to prevent the engagement ends 46 to 49 from being fatigued or deteriorated due to shock to be caused when fallen or due to long term unuse, the reels 12 and 13 are ensured to be locked. In addition, by winding the lock-engagement members at least once at a central portion thereof like a coil to form a hole as shown in FIGS. 8A and 8B, it is possible to maintain the resiliency to be high even if the lock-engagement members are small in size.
Furthermore, since the lock-engagement members 40 and 41 have certain resiliency, it is ensured that the lower engagement ends 47 and 49 are surely engaged between the teeth 18 and 19 of the reels 12 and 13, respectively, even if there is a dispersion in a distance of slide movement of the slide body 22. In addition, the resiliency of the lock-engagement members 40 and 41 makes it no longer necessary to prepare a spring for urging the lower engagement ends toward the reels 12 and 13, so that the number of assembly parts decreased. Thus, the video tape cassette can be readily assembled. Accordingly, the invention is suitably applied to a small-sized tape cassette.
In the above mentioned embodiment, the upper engagement ends 46 and 48 have different shapes from those of the lower engagement ends 47 and 49. However, it should be noted that the upper engagement ends 46 and 48 may have the same shapes as those of the lower engagement ends 47 and 49 when viewed with respect to a center of the coil portions 44 and 45. This eliminates restriction about orientation and top and bottom in assembling of the lock-engagement members 40 and 41, so that the number of assembly steps is decreased to facilitate the assembling.
In the above mentioned embodiment, the lock-engagement members 40 and 41 are wound at least once at a central portion thereof like a coil to form a hole, and the support members 100 and 101 are in the form of shafts over which the coil of the lock-engagement members 40 and 41 are configured. In an alternative, the lock-engagement members may be designed not to have such a hole. For instance, the lock-engagement members are designed to be bent at a central portion thereof, and there are formed on a cassette half a plurality of shaft-like members or ribs which are suitably bent for positioning the bending portions of the lock-engagement members for rotation.
As described above, in the magnetic tape cassette made in accordance with the present invention, the lock-engagement members made of metal having certain resiliency are rotatably supported with the standing shafts disposed in the vicinity of the slide body. One of the engagement ends of the lock-engagement members is engaged to the slide body, while the other engagement end is engaged to the teeth formed at a circumference of the reel with one of engagement ends of the lock-engagement members being engaged to the slide body.
Thus, in accordance with the invention, it is possible to prevent the engagement ends from being fatigued or deteriorated due to shocks received when the tape cassette is dropped or due to long term unuse or preservation, the reels are ensured to be locked. In addition, since the lock-engagement members have certain resiliency even if they are small in size, it is no longer necessary to prepare a spring for urging the engagement ends toward the reels. The number of assembly parts decreases hence to simplify the assembling. Accordingly, the invention can be suitably applied to a small-sized tape cassette. | A cassette for magnetic tape includes a pair of cassette halves cooperating with each other to form a cassette body; a pair of reels disposed rotatably in one of the cassette halves to wind the magnetic tape around the reels, each of the reels including a flange having a plurality of teeth formed at a circumference of the flange; and a reel locking assembly engaging the flanges for preventing rotation of the reels, the reel locking assembly includes: a slide body slidably disposed between the reels for sliding movement in a front-rear direction of the cassette body; an urging member urging the slide body towards a front of the cassette body; a pair of support members each disposed on a respective side of the slide body; and a pair of lock-engagement members, each having a central portion which is supported rotatably by a respective one of the support members, the lock-engagement members being made of a resilient spring wire rod. Each of the lock-engagement members further includes a first engagement end engaged to the slide body and a second engagement end which is enabled to engage the teeth of one of the flanges when the slide body is positioned towards the front of the cassette body. | 6 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/363,144, filed Mar. 8, 2002. The entire teachings of the above application are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to wireless communication systems and in particular to a compact, configurable antenna apparatus for use with a portable subscriber unit.
BACKGROUND OF THE INVENTION
Code Division Multiple Access (CDMA) modulation and other spread spectrum techniques now find widespread application in wireless systems such as cellular mobile telephones, wireless local area networks and similar systems. In these systems a connection is provided between a central hub or base station and one or more mobile or remote subscriber units. The base station typically includes a specialized antenna for sending forward link radio signals to the mobile subscriber units and for receiving reverse link radio signals transmitted from the mobile units. Each mobile subscriber unit also contains its own antenna, for the reception of the forward link signals and for transmission of reverse link signals. A typical mobile subscriber unit may for example, be a digital cellular telephone handset or a personal digital assistant having an incorporated cellular modem, or other wireless data device. In CDMA systems, multiple mobile subscriber units are typically transmitting and receiving signals on the same carrier frequency at the same time. Unique modulation codes distinguish the signals originating from or intended to be sent to individual subscriber units.
Other wireless access techniques also use spread spectrum for communications between a centralized unit and one or more remote or mobile units. These include the local area network standard promulgated by the Institute of the Electrical and Electronic Engineers (IEEE) 802.11 and the industry developed wireless Bluetooth standard.
The most common antenna used in a mobile subscriber unit is a monopole. A monopole antenna most often consists of a single wire or other elongated metallic element. A signal transmitted from such a monopole antenna is generally omnidirectional in nature. That is, the signal is sent with approximately the same signal power in all directions in a generally horizontal plane. Reception of a signal with a monopole antenna element is likewise omnidirectional. A monopole antenna therefore cannot differentiate between signals originating from one direction versus a different signal originating from another direction. Although most monopole antennas do not produce significant radiation in the elevation plane, the expected antenna pattern in three dimensions is typically a donut-like toroidal shape, with the antenna element located at the center of the donut hole.
Unfortunately, CDMA communication systems are typically interference limited. That is, as more and more subscriber units become active within a particular area and share access to the same base station, interference increases among them, and thus so does the bit error rate they experience. To maintain system integrity in the face of increasing error rates, often the maximum data rate available to one or more users must be decreased, or the number of active units must be limited in order to clear the radio spectrum.
It is possible to eliminate excessive interference by using directive antenna at either the base station and/or the mobile units. Typically, a directive antenna beam pattern is achieved through the use of a phased array antenna at the base station. The phased array is electronically scanned or steered desired direction by controlling the phase angle of a signal input to each antenna element.
However, phased array antennas suffer decreased efficiency and gain as elements become electrically small as compared to the wavelength of the radiated signals. When phased arrays are used or attempted to be used in conjunction with a hand-held portable subscriber unit, the antenna array spacing must be relatively small and therefore antenna performance is correspondingly compromised.
SUMMARY OF THE INVENTION
Several considerations should be taken into account when designing an antenna for a hand-held wireless device. For example, careful consideration should be given to the electrical characteristics of the antenna so that propagating signals satisfy predetermined standards requirements such as, for example, bit error rate, signal to noise ratio or signal to noise plus interference ratio.
The antenna should also exhibit certain mechanical characteristics to satisfy the needs of a typical user. For example, the physical length of each element of the antenna array depends upon the transmit and receive signal frequency. If the antenna is configured as monopole, the length is typically a quarter length of a signal frequency; for operation at 800 MegaHertz (MHz) (one of the more popular wireless frequency bands) a quarter wavelength monopole must typically be in the range 3.7″ long.
The antenna should furthermore present an esthetically pleasing appearance. Especially when used in a mobile or handheld portable unit, the whole device must remain relatively small and light with a shape that allows it to be easily carried. The antenna therefore must be mechanically simple and reliable.
In CDMA systems in particular, another consideration involves controlling the capacity of the overall network. Some have provided for adaptive antenna arrays for use on a reverse link of a CDMA system in a handset. These directional antenna arrays can be used to increase system performance by decreasing interference from surrounding base-stations and/or other handsets. However, employing directional antennas on the reverse link complicates the performance of power control systems. That is, as in most wireless communication systems, the power level of signals radiated from handsets must be carefully controlled in order to avoid interference to other handsets so that the signal powers arrive at the base or other central site within a known power level range.
The present invention comes about from realizing the advantages of a mobile-subscriber device that uses a directional or other adaptive antenna array together with a separate transmit antenna. The directional adaptive antenna array, which is used only to receive signals, may typically consist of a number, N, of monopole antenna elements. These monopole elements can be formed as conductive segments on a portion of a dielectric substrate such as a printed circuit board. To complete the array, at least one element is designated as an active antenna element which is also disposed on the same substrate as one or more passive elements. In a preferred embodiment, the active element is disposed in the center of the array and the number of passive elements is two.
The separate transmit antenna may be integrated with the receive array. In a preferred embodiment, the transmit antenna is an omnidirectional element.
In other embodiments, the transmit antenna may be physically separated such as on the opposite side of the housing. That is, the receiver array may be positioned on the top of the handset with the transmit antenna on the lower portion thereof. In either case there is a separate receive and transmit interface port to the two antennas.
By utilizing a horizontally polarized transmit and vertically polarized receive array, isolation between the two antennae is improved.
CDMA based systems that exist today, such as IS-95 and IS-2000, have a capacity limitation problem. The limitations largely occur on the forward link, and result from some channel interference. This interference originates from both adjacent cells as well as from users within the same cell. Indeed, the difference in capacity between the forward and reverse links can be estimated to be as high as 50 to 100%. For voice and circuit switched data systems, the number of users that can be simultaneously supported is defined by the less capacious of the two links. Therefore, the limitation on the forward link actually limits the total number of users, and the excess capacity of the reverse link is wasted.
The use of an adaptive antenna in the subscriber unit on the receive side has the potential to increase the forward capacity to levels equal to or greater than the reverse capacity. This allows for a significant increase in the overall number of users without directly increasing the reverse capacity.
It is also envisioned that other types of systems, such as Time Division Duplex (TDD) systems, may also advantageously use the adaptive array for receive but to steer in an omnidirectional mode during transmit periods. The effect is achieves a similar result. It is also expected that when TDD systems are in a stationary or slow moving environment, a directional transmit may also be able to be utilized.
In accordance with its key aspects, the present invention consists of an antenna system in which an adaptive array is used for receiving signals and an omnidirectional antenna is used for transmitting. In preferred embodiments, the adaptive antenna is integrated into the housing of a handheld wireless communication unit, such as a mobile telephone unit, personal digital assistant or the like.
The adaptive array used for receive mode is preferably an array that uses parasitic, passive elements to achieve directionality.
In further aspects, the omnidirectional transmit antenna is physically and/or electrically separated from the receiver array. The omnidirectional transmit antenna may be integrated at a different polarity. For example, a vertically polarized receive array may have a horizontally polarized transmit element. In other instances, the separation can be provided by a physical distance such as by integrating the transmit antenna and the base of a handheld telephone unit.
The exact type of Radio Frequency (RF) modulation associated with the invention may be of many different types. For example, the invention can be utilized in Code Division Multiple Access (CDMA) systems as well as other Orthogonal Frequency Division Multiplexing (OFDM) or spread spectrum systems.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is a high level schematic diagram of a wireless communication device incorporating an adaptive antenna array.
FIGS. 2A-2C show various arrangements in which a horizontally polarized, or predominantly horizontally polarized, omnidirectional transmit antenna is incorporated within the same device.
FIGS. 3A-3C illustrate an alternate embodiment for the transmit antenna, mounted on the backside of a handset.
FIG. 4 is a more detailed plan of a three element receive array.
FIG. 5 is a circuit diagram showing one possible feed structure for the array.
FIG. 6 is a schematic diagram illustrating how the array can be integrated into a handset.
FIGS. 7A-7C illustrate a three-dimensional radiation pattern, azimuthal pattern and elevational pattern for the adaptive array.
FIGS. 8A-8C illustrate the gain patterns of a horizontal monopole transmit element in the three-dimensional, azimuthal and elevational planes.
FIGS. 9A-9C illustrate gain patterns of the bent horizontal monopole element operating in a PCS radio frequency band.
FIGS. 10A-10C illustrate three-dimensional, azimuthal, and elevational patterns for a bent monopole transmit element and its affect on the receive array.
DETAILED DESCRIPTION OF THE INVENTION
A description of preferred embodiments of the invention follows.
Turning attention now to the drawings, FIG. 1 illustrates a wireless device 100 that consists of a housing 110 having incorporated therein an antenna array 120 . In general the device 100 is some form of wireless communications device, such as a cellular mobile handset, or a personal digital assistant such as a Palm Pilot.
The antenna array 100 provides for directional reception of forward link radio signals. The forward link signals may be transmitted from a base station, in the case of a cellular handset 100 , or from a access point, in the case of a wireless data unit 100 making use of wireless local area network (WLAN) protocols. By directively receiving signals originating more or less from the location of a particular base station and/or access point, the antenna array 120 assists in reducing the overall effect of intercell interference and multipath fading for the mobile unit 100 . Moreover, as will be understood shortly, since antenna beam patterns generated by the antenna array extend outward in a desired direction, but are attenuated in most other directions, less power is required for effective transmission by the base station.
In an example embodiment, the antenna array 120 consists of a center element 102 and a pair of passive elements 104 , one on each side thereof. As will be understood shortly, the passive elements 104 can each be operated in either a reflective or directive mode; it is through this expediency that the array 120 can be steered to a particular direction. Although this embodiment shows three elements, it should be understood that the array 120 is not so limited, and that one, four, or even more passive elements may be included. Yet other embodiments are possible for the antenna array such as phased array, where the center element 102 is absent and the other elements are themselves used as active elements, together with active signal combining circuitry. We believe that a simple N passive element array is preferred, however, because of its low cost and high radiation efficiency.
FIGS. 2A-2C illustrate various possible placements for a separate transmit antenna 200 in accordance with the present invention. In the embodiment shown in FIG. 2A , the transmit antenna 200 is placed on the same circuit board as the antenna array 120 . In this particular embodiment, the transmit antenna 200 has a horizontal orientation as opposed to the vertically oriented elements of the receiver array 120 . This orthogonal arrangement provides for greater isolation between the two antenna sets.
In an alternate embodiment shown in FIG. 2B , the transmit antenna 200 can be placed at the lower end of the handset 110 housing. This provides for even more electromagnetic isolation due to the physical distance between the horizontal element 200 and the elements of the receive array 120 . This also tends to move a high power microwave region associated with the transmit antenna 200 closer to a region of the user's chin, rather than the user's brain.
In still other embodiments, as shown in FIG. 2C , an end portion of the transmit antenna 200 may be bent. The bent portion, which itself may then become more or less parallel with the elements of the directional array, allows for more design freedom. For example, this type of antenna can be used at a lower frequency where the overall length of the antenna must be longer but must still fit within the width of the handset. The bent element 200 might also be used to accommodate other components within the handset 110 such as a keypad. The bent arrangement also avoids radiation in the horizontal plane when the handset is held near a vertical position. This can provide for improved performance in all orientations of the handset 110 .
FIGS. 3A-3C show still further possible embodiments of the transmit element 200 , with FIG. 3A being a side view and FIG. 3B being a rear view of the housing 110 . Here the transmit antenna 200 is a relatively short length for operation at relatively high frequencies such as in Personal Communication Services (PCS) type frequencies that typically are in the range of 1900 MegaHertz (MHz). However the element 200 can be provided with a hinge 210 allowing for an elongated section 220 to provide dual mode operation. The overall length of the fully deployed antenna element can be made to resonate at a lower frequency, such as the 800 (MHz) frequency associated with standard cellular telephone communication. The hinged or flipping arrangement for the element 200 assures that it can either resonate within one band or the other. It is therefore preferred to sliding or telescoping arrangements which might lead to the user not fully deploying the element 200 at the proper length.
In this embodiment a feedpoint 230 associated with the transmit antenna 200 may actually be placed in an offset position that is not completely at one end of the element 200 . This offset feedpoint location 230 allows the resonant length ratio to fit the 1900/800 MHz frequency ratio.
FIG. 4 is more detailed view of the adaptive directional array 110 . Here the array 110 is disposed on portions of a dielectric substrate such as a printed circuit board, including the center element 102 and passive elements 104 A and 104 C previously described. Each of the passive elements 104 can be operated in a reflective or directive mode as will be understood shortly.
The center element 102 comprises a conductive radiator 106 disposed on the dielectric substrate 108 . The passive elements 104 A and 104 C themselves each have an upper conductive segment 110 A and 110 C as well as a corresponding lower conductive segment 112 A and 112 C. These segments 110 A, 110 C, 112 A, and 112 C are also disposed on the dielectric substrate 108 . The lower conductive segments 112 A and 112 C are in general grounded. Also, in general, the upper segments 110 A and 110 C and the lower 112 A and 112 C are of equal length.
When the upper conductive segment of one of the passive elements 104 , for example the upper conductive segment 110 A, is connected to the respective lower conductive segment 112 A, the passive element 104 A operates in a reflective mode. This results in received Radio Frequency (RF) energy being reflected back from the passive element 104 A towards its source.
When the upper conductive segment 110 A is open (i.e., not connected to the lower conductive segment 112 A or other ground potential) the passive element 104 A operates in a directive mode, in which the passive element 104 A essentially is invisible to the propagating RF energy which passes therethrough.
In one embodiment, the center element 102 and the passive elements 104 A and 104 D are fabricated from a single dielectric substrate such a printed circuit board with the respective elements disposed thereon. The passive elements 104 A and 104 C can also be disposed on a deformable or flexible substrate or attached to one surface of the center element 102 as well.
A microelectronics module 122 , including respective switch modules 116 A and 116 C, may also be disposed on the same substrate 108 with conductive traces 124 being provided therebetween. The signals carried on the conductive traces 124 control the state of the components within the microelectronic modules 116 A and 116 C that achieve particular operating states for the passive elements 104 A and 104 C, e.g., to place them in either the reflective or directive state as described above. Further connected to the microelectronics module 122 is an interface 125 for providing electrical signal control connectivity between the array 120 and an external controller device such as located in the remainder of the handset 100 . Interface 125 can be constructed from either a rigid or flexible material such as ribbon cable or other connector, for example.
FIG. 5 illustrates one possible feed structure for the array 120 in more detail. A switch control and driver 142 associated with the electronics module 122 provides logic control signals to each of the respective control modules 116 A and 116 C associated with the respective elements 104 A and 104 C. For example, each such control module 116 may have associated with it a switch S 1 or S 2 and two impedances Z 1 and Z 2 . The state of the switches S 1 or S 2 provides for connection states of either connecting the first impedance Z 1 or the second impedance Z 2 . In a preferred embodiment, the second impedance Z 2 may be 0 ohms and the first impedance Z 1 may be infinite, thus providing the desired short circuit to ground or open circuit. However, it should be understood that other values of the impedances Z 1 and Z 2 are possible, such as various reactive values.
Here it is also evident that the center element 102 is being directly driven to the receiver circuitry 300 associated with the handset. Thus, unlike other types of directive arrays, this particular directive array 120 has an advantage in that it is quite simple in operation, and complex combiners and the like are not necessary.
FIG. 6 is a exploded view of one possible implementation showing the directive array 120 formed on a printed circuit board and placed within a rear cover of a handset, for example. A center module 410 may include electronic circuitry, radio reception and transmission equipment, and the like. A final module 420 may serve as, for example, a front cover of the device. What is important to see here is that the printed circuit board implementation of the 100 can be easily fit within a handset form factor.
FIGS. 7A and 7B are antenna patterns illustrating performance of the array 120 as housed in a handset. The gain achievable is about 3 dBi. FIG. 7A is a three dimensional radiation pattern (in the X, Y and Z directions with respect to the referenced diagram shown for the handset 500 ).
FIG. 7B illustrates the azimuthal radiation pattern achievable when one of the elements is placed in directive mode and the other element is placed in reflective mode. The conducting element (which is made electrically longer in the Z direction), intercepts the received radio wave and reflects it. This creates a null in the negative X direction. Since there is no electromagnetic blockage in the +X direction, the wave passes through and creates a peak. The dimension of the circuit board in the X direction is not similar to the resonant wavelength, so that the signal is able to circulate all the way around the azimuthal plane.
The pattern in FIG. 7C , an elevational pattern, should be compared to an ideal symmetrical pattern to illustrate the effect of the housing 110 . The comparison shows that the overall effect on the azimuthal plane is a slight skewing of the beam, about 15° away from the X-axis. The pattern of FIG. 7C also illustrates “necking-down”, which is an effect of placing the radiating element in a handset. Good directivity is seen, at least along an approximate 180° azimuthal plane, although skewing is evident.
FIGS. 8A-8C are similar to FIGS. 7A-7C , although illustrate patterns the horizontal transmit antenna element 200 . This particular embodiment, with the reference physical drawing 510 shown in the upper left hand corner, was for a bent horizontal monopole element. The gain pattern in three-dimensions is relatively uniform, as shown in FIG. 8 C. The radiation pattern approaches a symmetric toroid with a gain of approximately 2.1 dBi. Again, the radiation pattern is offset somewhat through the effects of the handset enclosure 110 . However, relatively omnidirectional performances, other than in the azimuthal plane (as shown in FIG. 8B ) is the overall desired effect.
FIGS. 9A-9C are simulated gain patterns of a bent horizontal monopole designed for the 800 MHz cellular band, but operating in the higher frequency PCS band. The radiation pattern, as is evident from the view of FIG. 9A , is a cut toroid standing its “uncut” side. The gain is 4.2 dBi. The antenna is evidently radiating at its higher order mode, but is radiating effectively and thus can be used as a PCS radiator at 1900 MHz. As evident from FIGS. 9B and 9C , as at least some useable radiation pattern is seen in the azimuthal direction.
Finally, FIGS. 10A-10C illustrate the effect of adding a bent monopole together with the array 120 through a simulation process. In this simulation, a horizontal bent monopole 200 and the extending ground strip were added to the antenna array 120 ; only slight distortions were found. The beam is tilted upward by 15° (as shown in the elevational plot of FIG. 10 C). The gain provided is 4.7 dBi with a beamwidth of 145° in the azimuthal plane. This illustrates that the bent monopole does not appreciably affect the operation of the array in the directional modes.
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | An adaptive antenna used in a receive only mode with a separate omnidirectional transmit antenna. The arrangement is especially effective for small, handheld wireless devices. The transmit antenna maybe integrated with the receive array by utilizing a horizontally polarized transmit and vertically polarized receiver ray. In other embodiments, the transmit antenna may be physically separate and not integrated with the receive array. In either case there is separate receive and transmit signal port as an interface to radio transceiver equipment. The use of an adaptive antenna in the receive only direction has the potential to increase forward links capacity to levels equal to or greater than reverse link capacity. This allows for a significant increase in the overall number of users that may be active at the same time in a wireless system. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to detection systems in the realm of speaker verification (or speaker identification, authentication or recognition) and in other applications, such as radar detection, fire alarms, visual (face) detection and many others.
BACKGROUND OF THE INVENTION
Generally, the functionality of detection systems is defined by the capability to analyze a certain input sample (for example, a speech recording, a video or radar signal, etc.), compare it to a particular “claimed” or hypothesized pre-stored sample (e.g., a template or model) and to decide whether the observed test sample and the pre-stored sample match or not (i.e., to accept or reject the claim). The detection task can also be extended in a broader sense to cases involving a mixture of input samples, with the objective of detecting a particular claimed target within this mixture.
The quality of detection systems is measured primarily by evaluating two types of error (i.e., the expected values of such errors): “False Alarm Rate”, and “Miss Rate”. Low values of both measurements reflect more accurate systems. Typically, detection systems are trained/optimized according to criteria that minimize the two error rates simultaneously and along all operating points of the detection system. To such criteria belong maximum entropy, linear discriminative analysis, and indirectly, maximum likelihood.
To date, efforts towards such minimization have not yielded sufficiently desirable results. A need has therefore been recognized in connection with providing an arrangement that surpasses the performance hitherto encountered.
SUMMARY OF THE INVENTION
In accordance with at least one presently preferred embodiment of the present invention, for a given operating point range, with an associated detection “cost”, the detection cost is preferably reduced by essentially trading off the system error in the area of interest with areas essentially “outside” that interest. Among the advantages achieved thereby are higher optimization gain and better generalization.
From a measurable Detection Error Tradeoff (DET) curve of the given detection system, a criterion is preferably derived, such that its minimization provably leads to detection cost reduction in the area of interest. The criterion allows for selective access to the slope and offset of the DET curve (a line in case of normally distributed detection scores, a curve approximated by mixture of Gaussians in case of other distributions). By modifying the slope of the DET curve, the behavior of the detection system is changed favorably with respect to the given area of interest.
Experimental observations show that the slope component of this new criterion exhibits significantly better generalization behavior compared to the conventional methods as described herein. The criterion is applicable to any detection system which works on the basis of detection scores that are mixture-Gaussian distributed. An implementation description is exercised herebelow in connection with an existing text-independent speaker verification system as described in Navratil, J., Chaudhari, U. V., Ramaswamy, G. N., “Speaker verification using target and background dependent linear transforms and multi-system fusion,” (Proceedings of EUROSPEECH-01, Aalborg, Denmark, September 2001), where the optimization is applied on the feature space level of each single system, as well as for combining multiple systems.
In summary, the present invention relates, in one aspect, to an apparatus for facilitating detection in a detection system, the apparatus comprising: an input arrangement which accepts input data comprising true target data and non-target data; a detection arrangement which evaluates the input data and derives scores from the input data; and an evaluation arrangement which evaluates the scores and which successively prompts revision of at least one aspect associated with the scores until the scores reach a predetermined quality; wherein the evaluation arrangement is adapted to minimize a criterion associated with a detection error tradeoff relating to the scores.
In an additional aspect, the present invention relates to a method of facilitating detection in a detection system, the method comprising steps of: accepting input data comprising true target data and non-target data; evaluating the input data and deriving scores from the input data; and evaluating the scores and then successively prompting revision of at least one aspect associated with the scores until the scores reach a predetermined quality; wherein the step of evaluating the scores comprises minimizing a criterion associated with a detection error tradeoff relating to the scores.
In a further aspect, the present invention relates to a program storage device readable by machine, tangibly embodying a program of instructions executable by the machine to perform method steps for facilitating detection in a detection system, the method comprising steps of: accepting input data comprising true target data and non-target data; evaluating the input data and deriving scores from the input data; and evaluating the scores and then successively prompting revision of at least one aspect associated with the scores until the scores reach a predetermined quality; wherein the step of evaluating the scores comprises minimizing a criterion associated with a detection error tradeoff relating to the scores.
For a better understanding of the present invention, together with other and further features and advantages thereof, reference is made to the following description, taken in conjunction with the accompanying drawings, and the scope of the invention will be pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates parameter optimization in a detection system.
FIG. 2 schematically illustrates the optimization of a linear combination of multiple detection systems.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
By way of background, the DET curve for assessment of detection systems was introduced in Martin, A. et al., “The DET Curve in Assessment of Detection Task Performance,” (Proceedings of EUROSPEECH-97, Rhodos, Greece, pp. 1895-1898) as an alternative to the Receiver Operating Characteristics (ROC) usually plotted on linear axes, offering a better viewability due to special, nonlinear scaling. The axes of the DET plot are scaled according to the normal error function defined as
Φ ( t ) = ∫ - ∞ t 1 2 π ⅇ - τ 2 2 ⅆ τ
with t denoting the threshold applied on the detection score.
Given a specific detection system that supplies real-valued scores for a trial (i.e., a test sample and a claimed model), the Detection Error Tradeoff Analysis Criterion (DETAC) is formulated for two cases of score distribution types: 1) the Gaussian, and 2) the Gaussian-Mixture distribution.
As regards, Gaussian Distributed Detection Scores, it should be noted that the DET curve generally appears as a straight line for these distributions. Assuming that the impostor (false claims) trial scores are normally distributed with mean μ 1 and standard deviation σ 1 , and the true target scores with μ 2 and σ 2 , the DETAC criterion is formulated in variants of constrained and unconstrained optimization, with an optimization parameter set θ, as follows:
Constrained Minimization of DETAC Slope:
θ*=arg min θ ±R (θ), subject to D (θ)≦0 (1)
Constrained Minimization of DETAC Bias:
θ*=arg min θ D (θ), subject to R (θ)=0 (2)
Unconstrained Minimization of DETAC:
θ*=arg min θ w R ( R (θ)− C R )+ w D ( D (θ)− C D ) (3)
where
R ( θ ) = w R ( σ 1 ( θ ) σ 2 ( θ ) - C R ) ,
is the Sigma-Ratio corresponding to the DET line slope
D ( θ ) = w D ( μ 1 ( θ ) - μ 2 ( θ ) σ 2 ( θ ) - C D )
is the Delta-Term corresponding to the DET line as and
w R , w D ∈R being arbitrary regulator constants and C R , C D ∈R the initial values of the Sigma-Ratio and the Delta-Term respectively.
The minimization (1) aims at reducing or increasing the slope of the DET line depending on the location of the operating point (“+” if the OP requires false alarm rate to be lower than that of the Equal-Error-Rate, “−” otherwise), while keeping the bias constant or smaller than the initial value. The minimization (2) aims at reducing the DET bias while keeping the slope constant. For (1) and (2) the reduction of the objective guarantees a reduction on both error types (False Alarm, Miss) for the given operating area on training data set.
The minimization (3) aims at reducing both weighted terms simultaneously. It represents a compromise between (1) and (2), which can be easily implemented with most optimization software packages. The distribution parameters σ 1,2 μ 1,2 are a function of the optimization set θ. This functional relationship depends on the particular system structure and implementation and has to be determined for each case individually. Later on, two examples for the most common speaker detection systems on the basis of Gaussian Mixture Models (GMM) are described.
In the case of non-Gaussian detection score distributions, the approximation by a mixture of Gaussian densities is used. The two error probabilities are written as a weighted sum of error components, each distributed with a mean and a standard deviation:
P M ( t ) = ∑ i π i e Mi ( t ) = ∑ i π i ∫ - ∞ t N ( τ , μ i , σ i ) ⅆ τ = ∑ i π i Φ ( t - μ i σ i )
(Probability of Miss)
and
P FA ( t ) = ∑ i π i e FA ( t ) = ∑ i π i ∫ t ∞ N ( τ , μ i , σ i ) ⅆ τ = ∑ i π i Φ ( μ i - t σ i )
(Probability of False Alarm).
Let F 0 (Sigma-Ratio, Delta-Term) denote the DETAC objective function for Gaussian distributed scores, i.e. one of the three introduced hereinabove. Then, the DETAC objective function for Gaussian mixture distributions can be defined as
F GM = ∑ i ∈ T _ j ∈ T β ij F 0 ( σ 1 i σ 2 j , μ 1 i - μ 2 j σ 2 j )
where T, T are the true target and the impostor trial sets respectively, β ij are pairwise component weights that sum up to 1. The weights should be proportional to the Bayes error between the components “i” and “j”, and one suitable function type is the Chernoff bound (upper bound on the Bayes error):
β ij =c ij √{square root over (π i π j )} e −u(0.5,σ 1i ,σ 2j ,μ 1i ,μ 2j )
where μ is a distance function, for 0.5 known as the Bhattacharyya distance (see Fukunaga, S., “Statistical pattern recognition,” Academic Press, 2nd Ed., 1990) and c are normalizing constants so that the weights sum up to 1.
The minimization is carried out using F GM as objective and with one of the choices (1)-(3) for F 0 .
The disclosure now turns to an example of a DETAC application in speaker verification.
As far as optimizing the models goes, the system on the basis of GMMs as described in Navratil, supra is preferably used. In this system, each target speaker has a model created in the initial training phase. In the test phase, the logarithmic likelihood-ratio score between the target model and a universal background model (UBM) is calculated. Given a test sequence of d-dimensional feature vectors, it can be shown that the average componentwise log-likelihood-ratio (LLR) can be written in a compact form
trAB+c
where “tr” denotes the matrix trace operator, A is an arbitrary d×d matrix transforming the feature space in each GMM component, B is a precomputed d×d matrix containing the model and the feature information and c is a constant.
Using the training sets T, T , the transform A can be optimized with respect the DETAC defined above, thus improving the detection accuracy of the baseline system. A is a full-rank transform and can be optimized either globally or on a speaker-dependent basis. (This example can be appreciated with reference to FIG. 1 , described in more detail further below.)
As far as the optimization of linear system combinations goes, it should be recognized that combining multiple detection systems is a well known method to improve the overall accuracy. An example of a simple combination is the linear combination of detection scores S output by N systems
s tot = ∑ k = 1 N w k s k
where a set of weights w is used. This set can be optimized by using the following forms of the Sigma-Ratio and Delta-Term of the DETAC:
Sigma - Term : a T S 1 a a T S 2 a Delta - Term : a T ( μ 1 - μ 2 ) a T S 2 a
in which S=cov(s)∈R N×N ;μ∈R N×1 are the covariances and means of the targets and impostor scores formed into N-dimensional vectors s i =[s i1 s i2 . . . s iN ] T , and α∈R N×1 is a projection vector containing the set of linear weights to be optimized.
After the DETAC optimization, the vector a represents the best set of weights with respect to the bias and slope implicit to DETAC, and the total score can be obtained as
s tot =α T s
(This example can be appreciated with reference to FIG. 2 , described in more detail further below.)
It should now be recognized that there are numerous model and system optimization methods available in the technical literature that allow for improving the accuracy of recognition systems (e.g., speaker verification systems). Typically, detection tasks are viewed as a special case of classification between two classes. Hence, most optimization techniques, applied to detection systems, concentrate on reducing the overall error caused by the class overlap in distributions. Some techniques try to achieve this via a naive approach, namely by optimizing each class independently (e.g., Maximum Likelihood techniques) other techniques aim at minimizing the Bayes error (discriminative techniques). (Background information on both types of techniques may be found in Duda R. et al., “Pattern Classification and Scene Analysis”, Wiley, 1973.) It can be shown that the Delta-Term of the DETAC function in (1)-(3) corresponds to some of these discriminative techniques, i.e. its minimization corresponds to minimizing the Bayes error.
However, in accordance with at least one presently preferred embodiment of the present invention, the Sigma-Ratio term of the DETAC has a different objective. Instead of minimizing the overall Bayes error of the classifier (detection system), its minimization leads to changes in the shape of the Bayes error area (class overlap). These changes may result in relative accuracy improvements in certain operating regions of the DET curve, outbalanced by error rate increases in others. Thus, DETAC can also represent a way of reshaping the Bayes error area in a controlled and provable way. From experimental observations, it appears that the process of reshaping the error area is easier to achieve than reducing the area of the error itself, which can be observed as a better generalization behavior of the optimized parameters.
It should be appreciated that while specific references have been made herein to the realm of speaker verification, DETAC can actually be applicable to essentially any detection system (e.g. as described in the “Field of the Invention” and “Background of the Invention” sections), in which some optimization parameters can be identified and their functional relationship to the DETAC parameters μ,σ can be determined or approximated, either analytically or heuristically. Additional conceivable applications include, but are not limited to, a wide range of “two-class” detection systems including biometric detection systems (e.g., not only those that face detection but those that involve fingerprint detection or any of a wide range of other types of bodily detection), automobile alarms, topic detection, language detection and even medical tests, including pregnancy tests.
FIG. 1 schematically illustrates parameter optimization in a detection system using DETAC in accordance with an embodiment of the present invention. Details relating to the different components or steps shown may be appreciated, in non-restrictive and illustrative fashion, from the discussion heretofore. As shown in FIG. 1 , data from a true target trial data set S 2 (indicated at 102 ) and from an imposter trial set S 1 (indicated at 104 ) are preferably input into a detection system 106 which includes model parameters 106 a. Output scores 108 , relating to both sets S 1 and S 2 , then preferably undergo evaluation via DETAC ( 110 ). If needed, model parameters 106 a will be updated (preferably in accordance with DETAC as described heretofore) and this cycle may preferably repeat itself until the output scores 108 reach or exceed a predetermined quality as discussed heretofore.
FIG. 2 schematically illustrates the optimization of a linear combination of multiple detection systems in accordance with an embodiment of the present invention. Again, details relating to the different components or steps shown may be appreciated, in non-restrictive and illustrative fashion, from the discussion heretofore. As shown in FIG. 2 , data from a true target trial data set S 2 (indicated at 202 ) and from an imposter trial set S 1 (indicated at 204 ) are preferably input into several detection systems 1 , 2 , . . . N (indicated at 206 , 208 and 210 ). In this case, a corresponding weighting factor (w 1 , w 2 , . . . wN; indicated at 212 , 214 and 216 ) associated with each system will be applied to output scores from each system. The weighted scores, relating to both sets S 1 and S 2 , then preferably undergo evaluation via DETAC ( 110 ). If needed, the weights w 1 , w 2 , . . . wN (at 212 , 214 , 216 ) will be updated (preferably in accordance with DETAC as described heretofore) and this cycle may preferably repeat itself until a combined final score (at 218 ) reaches or exceeds a predetermined quality as discussed heretofore.
It should be understood that the “impostor data” indicated at 104 and 204 in FIGS. 1 and 2 , respectively, may also be generally construed as “non-target data” in a wide variety of applications not only in speaker verification but in many others, such as those referred to heretofore.
It is to be understood that the present invention, in accordance with at least one presently preferred embodiment, includes an input arrangement which accepts input data comprising true target data and non-target data, a detection arrangement which evaluates the input data and derives scores from the input data, and an evaluation arrangement which evaluates the scores and which successively prompts revision of at least one aspect associated with the scores until the scores reach a predetermined quality. Together, the input arrangement, detection arrangement and evaluation arrangement may be implemented on at least one general-purpose computer running suitable software programs. These may also be implemented on at least one Integrated Circuit or part of at least one Integrated Circuit. Thus, it is to be understood that the invention may be implemented in hardware, software, or a combination of both.
If not otherwise stated herein, it is to be assumed that all patents, patent applications, patent publications and other publications (including web-based publications) mentioned and cited herein are hereby fully incorporated by reference herein as if set forth in their entirety herein.
Although illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be affected therein by one skilled in the art without departing from the scope or spirit of the invention. | In detection systems, such as speaker verification systems, for a given operating point range, with an associated detection “cost”, the detection cost is preferably reduced by essentially trading off the system error in the area of interest with areas essentially “outside” that interest. Among the advantages achieved thereby are higher optimization gain and better generalization. From a measurable Detection Error Tradeoff (DET) curve of the given detection system, a criterion is preferably derived, such that its minimization provably leads to detection cost reduction in the area of interest. The criterion allows for selective access to the slope and offset of the DET curve (a line in case of normally distributed detection scores, a curve approximated by mixture of Gaussians in case of other distributions). By modifying the slope of the DET curve, the behavior of the detection system is changed favorably with respect to the given area of interest. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Brazilian patent application No. MU8601558-3, filed on Apr. 17, 2006, for which the inventor is David Frederick Smith. Such application is fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The process of vaccinating eggs is important in the medical field and in poultry production. In medicine, eggs are used to incubate biological material utilized in the production of vaccines. In poultry production, the objective of in-egg vaccination is to protect the animals from endemic diseases.
[0003] Embryos receiving vaccine three days before hatching instead of the first day after hatching have more time to develop antibodies and consequently have a greater resistance to diseases. In this process, the vaccine ideally is applied directly into the amniotic fluid cavity of the egg, without penetration of the embryo. The incubation time for a chicken embryo is 21 days, and in-egg vaccination is normally performed three days prior to hatching, during the routine process of transferring the eggs from the incubator machine to the hatcher machine. The eggs that have previously been secured in incubator trays in which the eggs are fixed in a vertical position with the wider end of the egg up are now transferred in sets of one to four “flats” (trays) into hatcher baskets, where they are allowed to lay down in unencumbered positions so that they can hatch without injury.
[0004] The egg is composed of a shell, a membrane adhering to the inside of the shell, an interior membrane holding the embryo within the amniotic fluid, and an area between the two membranes holding the allantoidal fluid. As the egg is incubated, the outer membrane gradually separates from the shell, creating an air cell. This air cell is located in the top of the egg as per its position in the incubator tray. The process of vaccinating in-egg must be done with care to avoid cracking the egg shell or penetrating the embryo, either of which can be fatal to the embryo.
[0005] To distribute the vaccine to the injectors, the technology-taught by U.S. Pat. No. 6,240,877 utilizes a sealed pressurized air chamber constructed of rigid acrylic within which air pressure is applied to a collapsible plastic vaccine bag suspended within the chamber, forcing the liquid vaccine from the bag into the distribution system. The chamber is composed of a rigid acrylic chamber that is secured into a base plate, forming a tight seal. One or more vaccine bags are placed on a holder within the chamber that supports the bag in an upright position and flexible tubing is connected to an adapter on the bottom of the bag. The flexible tubing passes through a sealed “O” ring in the base of the chamber. This tubing is the vaccine distribution line and is connected to a distribution manifold that distributes the vaccine to the injectors. Compressed air is fed into the chamber and the vaccine bag is put under pressure in order to force the vaccine to the injectors. The injectors are opened and closed in a timed operation to deliver vaccine to the eggs.
[0006] A major problem with the device taught by the '877 patent is safety. The rigid acrylic chamber is kept constantly under pressure from compressed air. This pressure places strain on the internal surface area of the chamber, and as the stress of usage progresses the plastic begins to weaken. Furthermore, any mishandling of the chamber during cleaning or storage can cause fractures which might not be apparent to the operator. If this chamber should rupture while under pressure, shredded pieces of plastic could cause injury to the operators. Another serious problem with the device taught by the '877 patent could occur in the course of the routine working day when replacing the used vaccine bag for a new bag full of vaccine. To change the vaccine bag it is necessary to first remove all pressure from the chamber. If an inattentive employee does not drain the pressure before removing the chamber, the chamber would be forced off the base with an explosive pressure that could cause serious injury.
[0007] There is also a problem with the accuracy of vaccine dosage in the device taught by the '877 patent. To distribute vaccine into the vaccination system, the compressed air exerts pressure on the vaccine bag, forcing the vaccine into the flexible tubing leading to the vaccine distribution manifold. From the distribution manifold, the vaccine continues on to the individual injectors that receive a timed amount of vaccine. A problem occurs because of fluctuations in the pressure being exerted on the vaccine bag in the pressure chamber. This pressure is read and corrected within the chamber. However, the causes of the change in pressure occur at the individual needles where the vaccine is injected. When the needles puncture the eggs and the vaccine begins to be injected, there is an immediate drop in pressure in the vaccine line which influences how much vaccine flows through the line. The response to that pressure drop will only begin to occur when the pressure change reaches the chamber where the pressure sensor reads the drop and then more air pressure is applied. By that time, the injection process will have been completed and while more air pressure is being applied within the chamber, the vaccine lines are closed and pressure within the lines is increasing. In other words, by measuring the pressure in the pressure chamber at the farthest point from where the line opens and closes to deliver vaccine, the pressure control system is always working to compensate for changes that have already occurred, and this affects vaccine dosage. It can also affect the quality of the vaccine, which is pressure sensitive. If the pressure on the vaccine goes above 5 psi it can damage and perhaps crush the vaccine cells. Since the pressure in the device taught by the '877 patent is measured and controlled in the chamber, there are no direct controls on the pressure in the vaccine line. In fact, the pressure in the line is not known. Even though the pressure is maintained at a safe level in the chamber, it is possible that at the ends of the vaccine lines, the pressure can rise above that safe pressure level.
[0008] Finally, the device taught by the '877 patent has no automatic turn-off system when the vaccine bags are empty. If the operator does not notice that the vaccine bags are empty, the vaccinator continues to operate without injecting vaccine.
[0009] The current technology for a platform securing injectors over eggs to be injected is taught by U.S. Pat. No. 5,136,979. The device taught by the '979 patent utilizes a platform composed of two plates, a stabilizer plate and a tooling plate, which are attached together so that they raise and lower as one unit, with aligned holes in each through which injectors are guided. The plates are fixed to air cylinders that raise and lower the plates by the addition or subtraction of air. These air cylinders are secured to the vaccinator body. The entire tooling/stabilizer platform unit with injectors rests on the air cylinders that raise and lower the unit over flats of eggs so that when in movement, the plates and injectors are being propelled and supported by columns of air. In the resting position, the injectors are supported on the lower tooling plate. When the injectors are in position for injection, a narrow bladder located in the upper stabilizer plate is inflated with fluid to secure the superior portion of the injectors in place. Shell punches to open the egg and needles to deliver the vaccine within those punches are located within the injectors, and are driven from the injectors by compressed air.
[0010] In the device taught by the '979 patent, the tooling/stabilizer plates lower the injectors over the eggs to be vaccinated until the injectors make contact with the eggs. In the process of settling on the eggs, the injectors are raised slightly above the stabilizer plate and then the injectors are secured in position by the inflation of the narrow fluid bladder located in the upper stabilizer plate, which is the plate farther away from the eggs and therefore in a less firm position for securing the injectors. The tooling/stabilizer plates are suspended from the body of the vaccinator by columns of air within the air cylinders. There are no brake locks on the plates to secure them in position. During the vaccination process, subtle vibrations are created in the plates that can cause cracks in the eggs. These vibrations are caused when there is a change in the equilibrium between the force of the injector propelling the punch and needle into the eggs and the force of the air pressure in the air cylinders securing the plates over the eggs. At the moment when the punch makes contact with the eggshell, the injectors are forced upward slightly, causing the air in the cylinders securing the plates to compress. The sudden impact of the eggshell being penetrated causes disequilibrium between the downward force of the injectors and the upper force of the air cylinders, causing a slight rise in the tooling/stabilizer plates causing a vibration that is transferred to the eggs. After penetration, there is an inverse downward pressure on the eggs until equilibrium is reached. This vibration can be harmful to the eggs, causing an uneven force of penetration and possibly cracks to the eggs when the plates come down after the air pressure in the injection device has been released.
[0011] In addition, the device taught by the '979 patent has a narrow fluid bladder located in the superior stabilizer portion of the stabilizer plate and a tooling plate that secures the injector once it is in contact with the egg. Because the bladder secures only the very top portion of the injector at the point most distant from the egg, there remains the possibility for lateral movement of the lower part of the injector when the punch and needle make contact with the egg, which can cause hairline cracks on the eggshell. These cracks can induce a loss of fluids from the egg and cause embryonic death. The further the fluid bladder securing the injector is from the point of contact with the egg, the greater the possibility of lateral movement, and the greater that lateral movement can be.
[0012] Furthermore, the device taught by the '979 patent utilizes a stabilizer plate and a tooling plate platform to support injectors in their proper orientation over the eggs. Each vaccinator is manufactured for one particular size and type of egg flat. Because eggs vary greatly in size, many hatcheries have two or more types of incubator egg flats with different configurations for larger and smaller sized eggs. In these hatcheries, the use of the device of the '979 patent requires a separate vaccinator machine for each type and size of egg flat.
[0013] Finally, contamination is a very major concern and must be controlled since any contaminant entering the hole made by the injector has the potential to kill the embryo. The device of the '979 patent has two plates fixed to one another and it is extremely difficult to sanitize the joints between the two plates.
SUMMARY OF THE INVENTION
[0014] The present invention has been designed to resolve the safety, vaccine dosage, and vaccine control issues of the '877 patent. The present invention does not pressurize its vaccine chamber but instead uses an air bladder inside the chamber in the preferred embodiment that physically presses the vaccine bags against the sides of the chamber, forcing the vaccine through the flexible tubing that carries it to the distribution manifold. With this system the chamber is not pressurized and there is no danger of explosion or the chamber being launched into the air if carelessly opened while under pressure. The vaccine bags are hung from a hanger fixed to the base plate and between the bags is an air bladder that when inflated is slightly larger than the vaccine chamber. When the chamber is closed and latched over the base plate, the air bladder is filled with air to the point that pressure is applied to the vaccine bags on either side. The pressure continues to build until the desired pressure as programmed by the computer controller has been obtained. However, the pressure is within the air bladder which would rip if there were some damage to its structure or at worst explode to release the air without propelling hard acrylic material which could injure operators.
[0015] The important issue of vaccine dosage as influenced by pressure in the delivery system is resolved by measuring the vaccine line pressure at the most distant point from the chamber on the vaccine distribution manifold. When the needles release vaccine into the eggs, and there is an immediate drop in vaccine line pressure, the pressure sensor located on the distribution manifold of the preferred embodiment immediately senses the drop in vaccine line pressure and sends a signal to the microprocessor controlled micro-pressure regulator, which instantly decreases the pressure in the air bladder. As the flow to the needles stops, the increased pressure in the vaccine line is also immediately sensed by the pressure sensor that repeats the process, to decrease the pressure in the air bladder, thereby maintaining a constant pressure in the vaccine distribution line. The system guarantees that-the vaccine line pressure never surpasses 5 psi, which could damage vaccine cells and reduce the quality of vaccination. When the pressure in the system drops below 3 psi, this indicates that there is not enough vaccine in the vaccine bags to continue the vaccination process and the system shuts down automatically. This guarantees that no vaccination will be done without vaccine.
[0016] The present invention is directed to an apparatus that as part of the in-egg vaccinator controls the movement of the injector devices and is composed of two plates that operate independently from one another for specific purposes. The injector support plate is a plate that in certain embodiments may be fabricated from stainless steel with milled holes that are aligned according to the configuration of the eggs located in the incubator flat below it. The plate has a frame that is supported by two or more pneumatic air cylinders that raise and lower it. Individual injectors with needles that will perforate the eggshell and deliver the dosage of vaccine or other injectable material are fitted into the holes in the injector support plate. The caps on the injectors rest on the superior surface of the injector support plate. One of the principle features of the injector is a sensor located in the cap which emits signals when in contact with the injector support plate in order to control the passage of vaccine to the needle. -
[0017] One of the major improvements in the present invention relative to the device taught by the '979 patent is to use two independent plates which operate separately and individually, an injector alignment plate located closest to the eggs that is affixed in position directly to the structure of the vaccinator, and an injector support plate located in a superior position to the injector alignment plate that moves the injectors in a vertical up and down movement through the injector alignment plate to put the injectors in contact with the eggs to be vaccinated. Once the injectors are in contact with the eggs, they are held firmly in place by air tubes located in the milled spaces within the injector alignment plate which is the plate closest to the eggs and, therefore, the firmest position for securing the injectors.
[0018] In certain embodiments the present invention features large diameter longitudinal air tubes that are inserted into the injector alignment plate, the plate which is located closest to the eggs, with one air tube placed between each row of injectors. These air tubes have at least two high-pressure pneumatic air valves that rapidly inject large quantities of compressed air, filling the air tubes quickly and applying pressure to large surface areas of the lower portion of the injectors. The location of the air tube is critical to its ability to secure the injectors firmly in place. The closer the tubes are to the point of contact with the eggs, the less mobility is possible. Because of the relative large size of the air bag in the preferred embodiment, the injectors are held in a rigid position when in contact with the egg, minimizing the possibility of vertical or lateral movement. With the injector thus secured and the injector alignment plate being firmly fixed to the machine, there is a reduced possibility of vibrations being passed from the injector to the egg at time of penetration.
[0019] The present invention presented herein has in a preferred embodiment an injector alignment plate and an independent injector support plate that can be exchanged for plates for different sizes and configurations to be used in the same vaccinator. Utilizing the two independent components, one to lift and lower the injectors and the other to guide and secure the injectors, changing the components is an easy task. This operation takes less than ten minutes and does not disrupt the in-egg vaccination process. The present invention will save investment in equipment over the device taught by the '979 patent, which requires two machines if two different types of egg flats are being utilized.
[0020] The present invention further, in a preferred embodiment, has an injector support plate independent of the injector alignment plate that permits the use of an injector that has an electronic sensor embedded in the cap, which rests on the injector support plate in its normal raised position. When the injector support is lowered over the eggs, the injector cap is raised by the egg through the hole in the injector support plate. If for any reason, such as infertile eggs removed during candling, there is an empty space in the egg flat, the injector does not lift up from the injector support plate. An electronic sensor embedded into the injector cap then sends an electronic signal to the microprocessor, which inhibits the injector from injecting vaccine into the empty space. The saving of vaccine by not injecting into empty spaces represents a cost savings, since infertile and dead embryos average 7 to 10% of the eggs being vaccinated.
[0021] Further in the preferred embodiment of the present invention, having two independent and easily removable plates, the injector support plate and the injector alignment plate, separate from one another makes injector sanitization much more efficient. With the injector support plate being-separate and removable from the injector alignment plate it is a simple matter to sanitize between the two independent plates.
[0022] The second plate, the injector alignment plate, of the preferred embodiment can be fabricated from Delrim plastic or other high-density material and has milled holes having the same configuration of holes as the injector support plate and slightly larger in diameter, in order to align the injectors over the eggs to be vaccinated and allow some lateral movement of the injectors as they descend over the eggs. This plate is attached to the structure of the egg injection machine. It is rigid and immovable.
[0023] With the injector alignment plate firmly in its position, the injector support plate with the injectors is lowered by the air cylinders of a preferred embodiment of the present invention until the injectors pass through the corresponding holes in the alignment plate. The holes in the injector alignment plate are larger in diameter than the holes in the injector support plate to allow a 360-degree lateral movement of the injectors within the injector alignment plate. Inside the injector alignment plate, parallel to each row of injectors, there are large diameter cylindrical pneumatic air tubes made of an expandable polymer material that when deflated allow the free passage of the injector through the injector alignment plate holes. When the injectors are lowered into place above the eggs, high-pressure compressed air is injected through high-speed, large-capacity pneumatic valves into each air bag at two or more air connections located in the tubes to insure rapid uniform inflation.
[0024] The air tubes inflated from both ends become rigid structures, pressing firmly against the injectors on either side to insure that the injectors are immobilized. The positioning of these air tubes inside the injector alignment plate is very important to the integrity of the eggs since the injectors are being secured at the point just above the needle exit, allowing no play in the injectors as the needles makes contact with the eggshell. The position of the air tubes in the injector alignment plate at the point of the injector closest to the egg insures that the injector will suffer the least possible lateral movement at the moment of impact of the injection needle into the egg.
[0025] These and other features, objects and advantages of the present invention, as described above with respect to certain preferred embodiments of the present invention, will become better understood from a consideration of the following detailed description of the preferred embodiments and appended claims, in conjunction with the drawings as described following:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0026] FIG. 1 shows the side view of the vaccine chamber of a preferred embodiment of the present invention before beginning the vaccination process, with the “U” support affixed to the aluminum base of the chamber and the acrylic top filled over the “U” support with quick-connect fasteners fitting over the lip of the chamber and the air bag suspended from one of the three “U” support hooks. The air bag air pressure line passes through the base of the chamber.
[0027] FIG. 2 shows the vaccine chamber front view of the vaccine chamber of a preferred embodiment of the present invention with two full vaccine bags before the vaccination process begins, suspended from hooks attached to the “U” structure and with vaccine tubing which is connected to the vaccination system. The air bag is deflated.
[0028] FIG. 3 shows the vaccine chamber of a preferred embodiment of the present invention during the vaccination process when the air bag is inflated, pressing against the vaccine bags and forcing the vaccine through the tubing and into the vaccination system.
[0029] FIG. 4 shows the vaccine chamber of a preferred embodiment of the present invention during the vaccination process when the air bladder is inflated, pressing against the vaccine bags and forcing the vaccine through the tubing to the distribution manifold with the pressure sensor on the point furthest from the vaccine bags. The pressure sensor is attached by air line to the microprocessor-controlled, micro-pressure regulator, which is attached to the air bladder via the air pressure line.
[0030] FIG. 5 is a side elevational view of the two plates of the preferred embodiment of the present invention, the injector alignment plate and the injector support plate, in the resting position before beginning the vaccination process, with the injector alignment plate affixed on the vaccinator structure and the injector support plate positioned on the base structure holding the pneumatic cylinders, and with the injectors resting on the injector support plate and the air tubes in the interior of the injector alignment plate deflated.
[0031] FIG. 6 is a side elevational view of the two plates of the preferred embodiment of the present invention, the injector alignment plate and the injector support plate, in position for vaccination, with the injector alignment plate in the same position as in FIG. 1 and the injector support plate at its lowest level, with the injectors resting on top of the eggs and the egg shells beings penetrated by the needles, and the caps of the injectors raised up from the injector support plate and the air tubes in the interior of the injector alignment plate inflated with air.
[0032] FIG. 7 is a side elevational view of the two plates of the preferred embodiment of the present invention, the injector alignment plate and the injector support plate, in position to exchange the plates for plates of different configurations, with the injector alignment plate in the same position as in FIGS. 1 and 2 and the injector support plate at its highest level, with the injectors raised in order to leave the injector alignment plate free to be removed from its quick connect fasteners.
[0033] FIG. 8 is a cut-away view of the interior of the injector alignment plate of a preferred embodiment of the present invention, showing the air tubes deflated to allow free passage of the injectors through the milled openings.
[0034] FIG. 9 is a cut-away view of the interior of the injector alignment plate of a preferred embodiment of the present invention showing the air tubes filled to maintain pressure over a large part of the body of the injector inside the plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] With reference now to FIGS. 1-9 , detailed explanations of the preferred embodiment of the present invention will be given. The purpose of the drawings is to further the explanation of the preferred embodiment, without limiting the scope of the invention as claimed herein.
[0036] FIG. 1 shows the vaccine chamber before beginning the vaccination process with the “U” support 17 affixed to the aluminum base of the chamber 18 and the acrylic top 19 filled over the “U” support with quick connect fasteners 20 fitting over the lip of the chamber 21 and the air bag 22 suspended from one of the three “U” support hooks 23 . The air bag feed line 24 passes through the base of the chamber.
[0037] FIG. 2 shows the vaccine chamber rotated 90° to show the two full vaccine bags 25 before the vaccination process begins, suspended from hooks 26 attached to the “U” structure 17 and with vaccine tubing 27 which is connected to the vaccination system. The air bag 22 is deflated.
[0038] FIG. 3 shows the vaccine chamber during the vaccination process when the air bag 22 is inflated, pressing against vaccine bags 25 and forcing the vaccine through tubing 27 and into the vaccination system.
[0039] FIG. 4 shows the vaccine chamber during the vaccination process when air bladder 22 is inflated, pressing against vaccine bags 25 and-forcing the vaccine through tubing 27 to distribution manifold 28 and into vaccine lines 33 , with pressure sensor 29 on the point furthest from vaccine bags 25 . The pressure sensor 29 is attached by an electrical line 30 to the microprocessor-controlled pressure regulator 31 that receives air 32 from a compressor to feed air bladder 22 via air pressure line 24 .
[0040] FIG. 5 shows the two plates, injector alignment plate 1 and injector support plate 8 , before initiating the vaccination process, with injector alignment plate 1 affixed to the structure of the vaccinator 2 by quick connect fasteners 3 with the plate supported by alignment pins 4 in the structural supports 5 . The injector alignment plate 1 has milled internal spaces that house air tubes 7 and circular openings through which pass injectors 6 . The injector support plate 8 is supported in its framework affixed to air cylinders 9 in its resting position with caps 10 of injectors 6 resting on top of injector support plate 8 with a vaccine entrance valve 11 and a microprocessor-controlled sensor 12 to emit signals indicating the presence of eggs.
[0041] FIG. 6 shows the vaccination process in which the air cylinder 9 lowers injector support plate 8 to rest injectors 6 on eggs 13 and needles 14 penetrate the egg shell and inject the vaccine into eggs 13 . The air tubes 7 inside injector alignment plate 1 are inflated with air in order to secure the injectors firmly in place, without movement, during the vaccination process. Because injectors 6 are resting on top of eggs 13 and not on injector support plate 8 , the injector caps 10 are slightly raised from the injector support plate 8 and the microprocessor-controlled sensor 12 emits a signal to open vaccine entrance valve 11 , allowing the vaccine to pass to each injector 6 and needle 14 to enter eggs 13 . In places where eggs are missing 15 , injector cap 10 continues to rest on injector support plate 8 and microprocessor-controlled sensor 12 emits a signal to maintain vaccine entrance valve 11 closed.
[0042] FIG. 7 shows an interval in the vaccination process, when injector alignment plate 1 and injector support plate 8 are exchanged so that egg flats of a different configuration can be utilized with the same vaccinator apparatus. The air cylinders 9 lift injector support plate 8 to its highest point in order to remove injectors 6 from their spaces in injector alignment plate 1 . The next step is to open quick-connect fasteners 3 and remove injector alignment plate 1 from alignment pins 4 and substitute the plate with another injector alignment plate 1 that will match the new configuration. Following this, injector support plate 8 is also substituted.
[0043] FIG. 8 shows a superior view of injector alignment plate 1 with air tubes 7 in their longitudinal formation and connections 16 at the extremities of air tubes 7 for the addition and removal of compressed air, before initiating the vaccination process, and therefore, deflated, allowing the free passage of injectors 6 through their cylindrical spaces in injector alignment plate 1 .
[0044] FIG. 9 shows a superior view of injector alignment plate 1 with air tubes 7 in their longitudinal formation and connections 16 at the extremities of air tubes 7 for the addition and removal of compressed air, inflated during the vaccination process, and therefore, pressing against the bodies of injectors 6 to inhibit any lateral movement of the injectors.
[0045] Referring again now to FIG. 1 , cylindrical vaccine chamber 19 of the preferred embodiment of the present invention, constructed of hard transparent material such as acrylic, is fixed to aluminum base 18 by quick connects latches 20 . There is no air-tight connection between vaccine chamber 19 and aluminum base 18 . Fixed to aluminum base 18 inside vaccine chamber 19 is a stainless steel support 17 for air bladder 22 and, as shown in FIGS. 2 and 3 , two vaccine bags 25 . Support 17 is in the form of an inverted “U”. The open end of the “U”, two parallel bars, are fixed to base plate 18 . The bars are parallel and within a few millimeters of the sides of vaccine chamber 19 and serve as a guide to align vaccine chamber 19 over base plate 18 . In the center of the closed end of the “U” there is a hook 23 from which is suspended air bladder 22 . On either side of the air bladder hook 23 are located hooks 26 for the vaccine bags.
[0046] Base plate 18 has three holes near the center of the plate. One hole is for air pressure line 24 that is connected to air bladder 22 and the other two are for vaccine bags 25 .
[0047] On start up of operation, with the device of the preferred embodiment of the present invention turned off, latches 20 securing vaccine chamber 19 to base plate 18 are released and vaccine chamber 19 is removed from base plate 18 . Two vaccine bags 25 are hung from vaccine bag hooks 23 on “U” support 17 . Special needles are attached to the two vaccine lines 27 passing through base plate 18 and these needles are pushed into place in the exit ports of vaccine bags 25 . Vaccine chamber 19 is then replaced over the support securing air bladder 22 and the vaccine bags 25 and fastened to base plate 18 with quick connectors 20 .
[0048] The device is now ready to be operated. When the vaccinator is turned on, the CPU verifies that the line pressure in distribution manifold 28 , as shown in FIG. 4 , is low and air pressure is applied to air bladder 22 in vaccine chamber 19 . At the same time the CPU automatically opens a purge distribution manifold valve to allow vaccine to flow into distribution manifold 28 . When air has been purged from distribution manifold 28 , the purge distribution manifold valve is turned off. The next step is to purge vaccine lines 33 from distribution manifold 28 to needles 14 . This is done manually by pressing the purge needle button on the touch screen.
[0049] Once air from vaccine lines 33 has been purged, the vaccinator is ready to operate. If the operators are not cautious and allow vaccine bags 25 to empty their contents before changing, the device automatically stops when the vaccine no longer is being forced from vaccine bags 25 . When there is no pressure from vaccine entering into distribution manifold 28 , the pressure will drop below 3.0 psi and the system will automatically shut down until new vaccine bags 25 have been placed in vaccine chamber 19 .
[0050] The vaccination process proceeds as follows, as shown in FIGS. 5 and 6 : An incubator egg flat is introduced into the vaccinator structure 2 and electronic sensors activate the injector support plate air cylinders 9 , lowering the injector support plate 8 and injectors 6 . These injectors 6 pass freely through the injector alignment plate 1 until they reach the eggs 13 . The eggs 13 in the incubator flats are normally at slight angles to the perpendicular injector alignment plate 1 above them. As injectors 6 come in contact with eggs 13 , the larger diameter of the openings in injector alignment plate 1 allows injectors 6 to adjust to the angle of eggs 13 , so that needles 14 will penetrate them perpendicularly.
[0051] When injector support plate 8 has reached its lowest point and injectors 6 are resting on eggs 13 , the electronic controls activate high-pressure air valves to fill air tubes 7 located inside the injector alignment plate 1 , as shown in FIG. 6 . These air tubes 7 are positioned between the rows of injectors 6 and on their outsides, as shown deflated in FIG. 8 and inflated in FIG. 9 . Once inflated, they completely fill all available space in the chamber, exerting a constant pressure on all the exposed surface area of injectors 6 . The position of the injector alignment plate 1 , closest to the needle 14 exit on each injector 6 , is the most ideal for firmly securing the injectors 6 since the origin of vibrations that can cause egg cracks comes from the needle 14 impact with the shell of eggs 13 .
[0052] When injectors 6 come to rest on eggs 13 , the injector caps 10 which have been resting on the upper side of the injector support plate 8 are slightly raised. If there is no egg 13 under any one injector 6 , as when an infertile egg had been removed during a previous candling process, that injector cap 10 will remain resting on the injector support plate 8 . The sensor in the injector cap 10 sends an electronic signal to the computer and no vaccine is released into that injector's needle 14 .
[0053] After each of the eggs 13 have been injected, the electronic controls signal the high-capacity pneumatic dump valves to remove the compressed air from air tubes 7 , eliminating the pressure against the injectors 6 inside the injector alignment plate 1 , leaving them to move freely. The injector support plate 8 is raised to its starting position, removing injectors 6 from contact with eggs 13 .
[0054] Hatcheries will often have incubator flats with different configurations to accommodate variations in egg 13 size. The injector support and injector alignment plates, 8 and 1 , respectively, are milled for a specific egg flat configuration. However, the preferred embodiment is designed for an easy and rapid exchange of plates so that one vaccinator can be used with all of the configurations of flats manufactured for any one model of incubator. To do the plate exchange, electronic controls signal pneumatic air cylinders 9 to raise injector support plate 8 to its highest position, as shown in FIG. 7 , removing in this process injectors 6 from injector alignment plate 1 . With injector alignment plate 1 free of injectors 6 , injector alignment plate 1 is removed by undoing quick-connect fasteners 3 securing injector alignment plate 1 to vaccinator frame 2 , removing it from alignment pins 4 and substituting it with the appropriate injector alignment plate 1 for the next incubator egg flat to be injected. Then through the electronic controls, injector support plate 8 is lowered to its operating position and because the injector support plate 8 holes no longer align with the new injector alignment plate 1 , the injectors remain above the new injector alignment plate 1 .
[0055] The injector support plate 8 corresponding with the newly placed injector alignment plate 1 is selected and a thin flat aluminum sheet with no holes (not shown) is placed on top of the new injector support plate 8 . The new injector support plate 8 with the aluminum sheet covering the holes is placed on top of the injector support plate 8 to be substituted and gently pushed, raising injectors 6 from the plate being substituted and letting them slide onto the plate being inserted. When the new injector support plate 8 is in position, the injector support plate 8 being substituted can be easily removed by sliding it from beneath the newly inserted injector support plate 8 . The aluminum sheet previously placed on the newly inserted injector support plate 8 should now be gently slid laterally off of the injector support plate 8 , manually guiding injectors 6 row by row into their appropriate holes.
[0056] After the aluminum plate has been removed from the injector support plate 8 and all injectors 6 are inserted into the appropriate holes the injection machine is ready to vaccinate the next eggs 13 . The plate exchange operation should take less than 10 minutes to perform.
[0057] The present invention has been described with reference to certain preferred and alternative embodiments that are intended to be exemplary only and not limiting to the full scope of the present invention as set forth in the appended claims. | An automatic vaccinator of eggs, consisting of a system for applying vaccine with a vaccine chamber in which vaccine bags are hung and with an air bag that, when expanded, forces the vaccine from the bags and through tubing to a distribution manifold and the injectors, so that the vaccine is delivered to the eggs, is disclosed. A pressure sensor is installed in the distribution manifold and connected to a regulator, measuring the pressure in the distribution manifold at the point farthest from the vaccine chamber and controlling the pressure in the air bag to maintain a uniform quantity of vaccine being injected into the eggs and turning off the vaccinator if the pressure falls below a critical level, signaling that the vaccine bags are empty. The mechanical unit includes a system to support, align and secure the injectors over the egg tray, composed of two plates that work independently, a support plate and an alignment plate. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. provisional patent application No. 62/342,102, filed May 26, 2016, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] One or more embodiments of the invention relates generally to illuminated wheels. More particularly, the invention relates to wheels and rims having embedded light emitting diode (LED) lights disposed therein for use in cars, trucks, recreational vehicles, all-terrain vehicles (ATVs), motorcycles, and the like.
2. Description of Prior Art and Related Information
[0003] The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon.
[0004] With the increasing popularity of LEDs, various uses have been proposed to use this lighting product. On vehicles, LED systems has been used, for example, to providing lighting effects under a vehicle, where the LED system is directed to shine a light down from the underside of the vehicle, onto a road surface.
[0005] More recently, adding lighting effects to other parts of the vehicle has been performed. This lighting has been applied to vehicles as a post-production, add-on modification. In some embodiments, LED systems have been attached to wheels, around headlights, around taillights, and the like.
[0006] These add-on systems, however, suffer from several issues. For example, often, a user must make modifications to their vehicle to add on such lighting systems. These modifications may include drilling holes, using attachment devices, such as glues or screws, running electrical wires, and the like. These modifications could void warranties and could provide installation difficulties. Moreover, when lighting systems are added to moving components, such as spinning wheels, there is a safety issue should the attachment means not be strong enough or eventually fail due to heat, moisture, rotational forces, or the like.
[0007] In view of the foregoing, it is clear that these traditional techniques are not perfect and leave room for more optimal approaches to provide lighting effects on wheels, rims, spinning rims and wheel covers for vehicles.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention provide a wheel comprising one or more integrated LEDs disposed within the wheel; a battery pack disposed in a central region of the wheel; a switch disposed in the central region of the wheel; and wiring interconnecting the LEDs with the battery pack.
[0009] Embodiments of the present invention further provide a motorcycle wheel comprising LEDs disposed within the wheel and on both sides thereof; a battery pack disposed in a central region of the wheel; a switch disposed in the central region of the wheel; and wiring disposed within the wheel interconnecting the LEDs with the battery pack.
[0010] In some embodiments, the switch is one of a motion switch, a photo switch and a remote switch. In some embodiments, the wiring is disposed within the wheel. In some embodiments, a cover is disposed over one or more of the one or more integrated LEDs. In some embodiments, the LEDs are disposed on both sides of the wheel. In some embodiments, the LEDs are disposed in a cutout formed in the wheel.
[0011] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements.
[0013] FIG. 1 is a front view of a vehicle wheel having integrated LEDs disposed therein according to exemplary embodiments of the present invention;
[0014] FIG. 2 is a cross-sectional view of the vehicle wheel of FIG. 1 ;
[0015] FIG. 3 is a cross-sectional view of the vehicle wheel of FIG. 1 as taken along line of FIG. 1 with the cover 14 removed for clarity;
[0016] FIG. 4 is a front view of a vehicle wheel having integrated LEDs disposed therein, further including an optional opaque or transparent cover disposed over the lights;
[0017] FIG. 5 is a cross-sectional view of the vehicle wheel of FIG. 4 ;
[0018] FIG. 6 is an exploded view of a motorcycle wheel having integrated LEDs disposed therein, according to an exemplary embodiment of the present invention;
[0019] FIG. 7 is an exploded view of an axle attachment for the motorcycle wheel of FIG. 6 ;
[0020] FIG. 8 is a side view of a motorcycle having the motorcycle wheels of FIG. 6 ;
[0021] FIG. 9 is a front perspective view of the motorcycle wheel of FIG. 6 ;
[0022] FIG. 10 is a side view of a motorcycle wheel having integrated LEDs disposed therein, according to an exemplary embodiment of the present invention; and
[0023] FIG. 11 is a side view of a motorcycle wheel having integrated LEDs disposed therein, according to an exemplary embodiment of the present invention.
[0024] Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale. The invention and its various embodiments can now be better understood by turning to the following detailed description wherein illustrated embodiments are described. It is to be expressly understood that the illustrated embodiments are set forth as examples and not by way of limitations on the invention as ultimately defined in the claims.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.
[0026] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0027] In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.
[0028] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.
[0029] The present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below.
[0030] A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary a variety of optional components are described to illustrate the wide variety of possible embodiments of the present invention.
[0031] As is well known to those skilled in the art, many careful considerations and compromises typically must be made when designing for the optimal configuration of a commercial implementation of any system, and in particular, the embodiments of the present invention. A commercial implementation in accordance with the spirit and teachings of the present invention may be configured according to the needs of the particular application, whereby any aspect(s), feature(s), function(s), result(s), component(s), approach(es), or step(s) of the teachings related to any described embodiment of the present invention may be suitably omitted, included, adapted, mixed and matched, or improved and/or optimized by those skilled in the art, using their average skills and known techniques, to achieve the desired implementation that addresses the needs of the particular application.
[0032] FIGS. 1 through 3 illustrate a wheel 10 for a vehicle that has lights, such as LEDs 12 , disposed therein. The LEDs 12 can be integrated into the wheel 10 and permanently attached thereto. Unlike conventional lighting, with the LEDs 12 integrated into the wheel 10 , there is no risk of the lighting coming off due to centrifugal force, failed adhesive, or the like. Moreover, unlike conventional, after-market add-on lighting, the integrated LED lighting of the present invention is created as an integral unit, with the wiring, switch and power supply all integrated into the wheel 10 . A battery cover 14 may cover many of the components at a central portion of the wheel 10 . Within the battery cover, as shown in FIG. 2 , the battery pack 26 may be disposed.
[0033] As shown in FIGS. 2 and 3 , wiring 18 may extend from the LEDs 12 to the battery pack 26 . In some embodiments, the wiring 18 may be embedded within the wheel. In other embodiments, the wiring 18 may run along a path and/or a channel formed on an inside portion of the wheel 10 .
[0034] In some embodiments, a switch (not shown, see FIG. 7 for an example of the switch which may be integrated below the battery cover 14 ) can be a remotely controlled switch, where the driver can choose when to power on or off the LEDs 12 . In other embodiments, the switch may be a motion detection switch, where motion of the wheel turns on the LEDs and they turn off automatically when the wheel stops moving. In either embodiments, a light sensor or diode may be used to keep the LEDs 12 turned off when a certain level of brightness is ambient or to automatically turn on the LEDs 12 when a predetermined level of darkness is present.
[0035] The power supply may be a photo cell to rechargeable battery pack 26 on cover of 14 . In some embodiments, a portion of the outer periphery of the wheel, such as a central hub or spokes 16 thereof, may be formed from solar panels, where the solar panels can charge the battery pack 26 . Typically, the battery pack 26 , LEDs 12 and solar panels are disposed uniformly about the wheel so that balance of the wheel is not changed by the LEDs 12 and its accompanying components.
[0036] The wheel 10 may include conventional components, as shown in FIG. 3 , such as the spindle cap 22 , lug nuts 20 and a brake rotor 24 , for example. The wheel 10 may have various widths 28 and diameters 30 as may be known in the art, depending on the particular vehicle with which the wheel is used.
[0037] In some embodiments, as shown in FIGS. 4 and 5 , a cover 32 may be disposed over the LEDs 12 . The cover 32 may serve several purposes, including protecting the LEDs 12 from physical or weather related damage, diffuse the light from the LEDs 12 , and provide an aesthetically pleasing appearance for the exterior of the wheel 10 . The cover 32 may be opaque, transparent, patterned, colored or the like. The cover 32 , of course, is an optional item that may or may not be present on the wheel 10 .
[0038] Referring now to FIGS. 6 and 7 , there is shown a motorcycle wheel 60 having integrated LEDs 12 formed therein. The motorcycle wheel 60 described with respect to this embodiment of the present invention can be similar to the wheel 10 described above, however the LEDs 12 would be disposed on both sides of the motorcycle wheel 60 .
[0039] Similar to the wheel 10 described above, the motorcycle wheel 60 can be formed with an integrated switch 74 and power supply, such as a battery 26 . The switch 74 can be a remote switch, a movement-triggered switch, or the like. The power supply is typically a rechargeable battery. The battery 26 may be charged with a solar panel (not shown), for example, disposed on at least a portion of the exterior of the motorcycle wheel. Thus, what is obtained is a self-contained, self-powered, integrated LED motorcycle wheel 60 , 76 , 90 , 100 , 110 .
[0040] The motorcycle wheel 60 , 76 , 90 , 100 , 110 can include wiring 18 connecting the battery 70 to the LEDs 12 . Typically, the wiring 18 is embedded into the wheel so as to be virtually invisible to the user and to prevent disconnection or tangling. An axle cover 14 can cover the battery 26 , switch 74 and related components.
[0041] In some embodiments, a connector ring 72 may be disposed within the axle cover 14 . The connector ring 72 may include concentric rings or hard wiring, for positive and negative power from the battery 26 . This allows each spoke containing a LED 12 to have easy access to a power terminal. Of course, other power connections may be used within the embodiments of the present invention.
[0042] Like the wheel 10 described above, the motorcycle wheel 60 can include optional covers 32 to be disposed over the LEDs 12 . The covers 32 may be opaque, transparent, formed with a pattern for diffusing light, or the like.
[0043] FIG. 8 shows a motorcycle 76 having the LED-integrated wheels 60 of the present invention, having LEDs 12 therein. Typically, the LEDs 12 are disposed on spokes 16 of the wheels 60 , but other configurations may be formed within the scope of the present invention. FIG. 8 shows an alternative type of cover 32 . In some embodiments, the LEDs 12 can be disposed at different locations on the wheel 60 and some or all may be covered with the covers 32 .
[0044] FIG. 9 shows an embodiment of a motorcycle wheel 90 having a plurality of LEDs 12 disposed along each spoke 16 . Optional covers 32 may be disposed over the LEDs 12 or over an entire length of the spoke 16 , as shown in FIG. 9 . In this manner, the light from the LEDs 12 may diffuse over the length of the cover 32 to provide a different lighting effect.
[0045] FIG. 10 shows a further embodiment of a motorcycle wheel 100 having LEDs 12 disposed therein. Optional covers 32 may be disposed over some or all of the LEDs 12 . Similarly, FIG. 11 shows a further embodiment of a motorcycle wheel 110 having LEDs 12 disposed therein. Optional covers 32 may be disposed over some or all of the LEDs 12 . In FIG. 11 , the wiring 114 is shown above the wheel, but is typically embedded within the wheel itself. The battery (not shown), switch (not shown) and like components may be disposed in a central region 14 of the wheel 110 .
[0046] While the above describes individual LEDs, multiple LEDs, such as an LED illumination bar may be used to generate light at a particular location. Furthermore, other designs may be incorporated to position light at desired locations. For example, a single LED may be used with fiber optics to create multiple illuminated locations at a location other than the LED itself. In some embodiments, fiber optics may be used to create various effects in addition to or in place of the LEDs.
[0047] The LEDs can be positioned at various locations on the base structure (the wheel, motorcycle wheel, or the like). For example, the LEDs may be positioned to direct light outward, away from the structure. In some embodiments, the LED's may be positioned to provide light toward the vehicle. In some embodiments, the LEDs may be positioned to provide light toward an interior of the wheel. In some embodiments, the LEDs may be positioned at a uniform distance from the hub of the wheel, providing a circular looking light when the wheel is moving. In other embodiments, the LEDs may be positioned at different locations, providing different effects when the wheel is in motion. The LEDs can be disposed in various colors, as desired for effect, safety of the like. In some embodiments, the LEDs can be multi-color LEDs or an LED illumination bar where the user can select the color of the LED by various manners known in the art.
[0048] While the above describes battery charging via solar panels, in some embodiments, the batteries may be charged by other means. For example, a motion-type charging system may be used, where motion of the wheel provides a charge to the battery. In some embodiments, a small current generation rotor and stator may be disposed within the wheel, where motion of the wheel generates power and power electronics may be incorporated into the battery, for example, for receiving a charging current from the generator. Of course, other charging systems, as may be known in the art, may be used within the scope of the present invention.
[0049] In some embodiments, the battery and charger may be eliminated from the LED system and a power generator may be used to generate power to light the LEDs when the vehicle is in motion. In this embodiment, power electronics may be used to prevent an over-current condition, where a maximum current is delivered to the LEDs once a given tire rotation is reached. In this embodiment, the switch may also be eliminated, as the rotation of the wheel itself would automatically turn on the LEDs, and they would automatically turn off when wheel rotation stops.
[0050] When a power supply, such as a battery, is used, various electrical connections may be used to connect the LEDs with the power supply. Typically, each LED may be wired to the battery, often with each “spoke” of LEDs wired in parallel with each other spoke, and each LED in the spoke wired in series. Of course, other wiring schemes may be used within the scope of the present invention.
[0051] All the features disclosed in this specification, including any accompanying abstract and drawings, may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0052] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of examples and that they should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different ones of the disclosed elements.
[0053] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification the generic structure, material or acts of which they represent a single species.
[0054] The definitions of the words or elements of the following claims are, therefore, defined in this specification to not only include the combination of elements which are literally set forth. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
[0055] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
[0056] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what incorporates the essential idea of the invention. | A wheel includes illumination built into the wheel, such as one or more LEDs disposed within the wheel itself. Unlike add-one lighting accessories, the LEDs may be integrated with the wheel to avoid disconnection from the wheel. The wheels can include a centrally located power supply and a switch. An optional cover may be disposed over the wheel. With the LEDs formed into the wheel, the optional covers may be flush with and shaped in a shape to match the wheel. The wheels may be wheels from cars, trucks, trailers, recreational vehicles, all-terrain vehicles, motorcycles and the like. When the wheel may be visible from both sides, as in the case with motorcycles, the LEDs may be disposed and integrated in both sides of the wheel. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of prior U.S. Provisional Application 62/197,798, filed on Jul. 28, 2015. The application is incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This invention relates to excavator attachments, and, in particular, to alignment tools for mounting and removing excavator attachments.
BACKGROUND
[0003] Excavators and backhoes of conventional construction, e.g. as described in Horton U.S. Pat. No. 7,322,133, the complete disclosure of which is incorporated herein by reference, are known in the prior art. By way of example, and with reference to FIGS. 12A and 12B of the present application, a hydraulic excavator 100 has a chassis 114 with a cab 118 for the operator. Extending from the chassis 114 is a boom 122 pivotally attached to the chassis, and a dipper stick 124 pivotally attached at the outboard end of the boom 122 . The dipper stick 124 connected to the boom arm 122 is moved in and out by means of a hydraulic boom cylinder 126 . An excavator attachment, e.g., a multi-shank ripper excavator attachment or tool 112 , as taught in the Horton '133 patent mentioned above, is removably connected to the dipper stick 124 at a stick pivot or pin 132 and to a 4-bar linkage 142 (connected to a hydraulic bucket cylinder 130 ) at a link pivot or pin 134 .
[0004] As described above, and referring also to FIG. 4 , excavator and backhoe attachments, such as buckets of different widths and types, e.g. ripper bucket 50 ( FIG. 6 ), ripper 52 ( FIGS. 8 ) and 112 ( FIGS. 12A and 12B ), and other tools, are typically connected to the machine stick 124 and to the link 142 by horizontal pins, i.e., stick or hinge pin 132 and link pin 134 . The stick pin 132 is held in place by engagement of a cross bolt 150 in aligned cross drilled hole 154 through the stick pin 132 and an associated stick pin locking collar 156 , and the link pin 134 is similarly held in place by engagement of a cross bolt 150 in aligned cross drilled hole 158 through the link pin 134 and an associated link pin locking collar 160 . The stick pin locking collar 156 and the link pin locking collar 160 are welded to the mounting plate (or “ear”) surface 166 of the excavator attachment. In turn, the cross bolts are secured in place by cooperating threaded nuts 152 at the opposite side of the collar 156 , thereby to resist rotation and movement of the pins 132 , 134 relative to the excavator attachment (only one cross bolt 150 and threaded nut 152 are shown, by way of example). This arrangement is described and discussed below in more detail, e.g., with reference to FIG. 4 ).
[0005] In other implementations, e.g., referring to FIG. 12B , a quick change coupler 164 may be used in place of the excavator attachment 128 , with the coupler 164 connected to the stick pivot pin 132 and link pin 134 by a set of two pins and an arrangement of hooks and locks that grab a second set of two pins mounted on the attachment.
[0006] In still another implementation, mechanical and hydraulic “pin-grabber” couplers can also simplify the action of connecting the excavator attachment 112 to the stick 124 and link 142 .
[0007] Changing excavator attachments 112 on an excavator or backhoe 100 without use of a quick change coupler 164 is recognized as being very difficult. For example, the operator must use a punch pin and a hammer to pound the linkage attachment pins 132 , 134 into place and out of place. When pounding the pins into place for a new connection, it is very difficult to align each pin so that the retention cross bolt holes 154 , 158 through the pins 132 , 134 and their respective locking collars 156 , 160 are aligned, in order to receive the cross bolts 150 . This method is known to be difficult, dangerous, messy, and to require two operators to accomplish it efficiently. Initially, to begin the process, the operator may gently rest the excavator attachment 112 on the ground; however, after a few short minutes, hydraulic valve spool leakage allows the combined weight of the stick 124 and boom 122 to cause the boom and stick to sag due to the hydraulic leakage drift. As a result, the entire weight of the stick and boom ends up resting on the linkage and attachment pins. During the changing operation, the operator tries to pound the pins 132 , 134 out of place, but when one pin finally pops out, e.g. the stick pin 132 , the stick 124 drops, and the punch pin (not shown) becomes trapped in the bucket bore, pinched by the stick. The operator must then get back into the machine cab and lift the 124 stick with the hydraulic power, thereby seeking to free the punch. The operator then has to pound the link pin 134 out of place in a similar fashion. After the first excavator attachment (e.g. tool 112 ) has been disconnected, the operator must swing the linkage over while attempting to align the stick bosses 170 ( FIG. 4 , where only one is seen) with the attachment bosses 172 (again, only one is seen). Most of the time, the second attachment is not sitting on a flat portion of the ground and it is not fully square to the machine, so aligning the stick 124 to the attachment bosses 172 is very difficult.
[0008] Once the stick and the replacement excavator attachment are aligned, the operator begins to pound the stick 132 into place from one side of the replacement attachment 112 ′, and then into the stick boss bore 170 , to complete the pivot. Again, because the stick 124 and boom 122 begin to slowly drift and sag lower due to hydraulic valve spool leakage, aligning the attachment pin bore 172 to the link bore 170 is very difficult. After the stick pin 132 is finally engaged into one side of the stick bore 170 , the pin must be pounded fully into place with a hammer until the end of the pin is visible on the opposite side of the attachment 112 ′. A cross bolt 150 is inserted to secure the pin 132 to the bucket 112 ′; however, it is very difficult to align the segments of locking bolt cross hole 158 (through the stick pin and through both sides of the stick pin locking collar 156 ) due to the weight of the stick 124 and boom 122 on the pin 132 , so the weight must again be lifted off the stick 124 , and the pin 132 rotated into alignment of the pin bolt hole segments so that the bolt 150 can be inserted. When the boom 122 and arm 120 are lifted, the weight of the attachment 112 again makes it difficult to rotate the pin 132 , thus requiring more pounding and difficulty. After assembly of the stick pivot pin 132 is complete, the link pin 134 can be pounded into place, typically with a little less difficulty, but the task is still considered to be difficult and dangerous.
[0009] In fact, many equipment operators have suffered pinched, or even severed, fingers performing this operation. The task can also be very messy due to the grease covering the components. For these reasons, quick couplers 164 are recognized as a huge benefit to the industry. Additionally, use of quick couplers may allow some operators to change tools many times per day, so not having to pound pins into position is a huge benefit. The easier it is to change attachments, the more likely it is that an operator will change attachments frequently in order to employ the attachment best suited for the job being performed. In contrast, prior to use of quick change couplers, an operator often felt forced to continue to use a tool ill-suited for a segment of job, thereby to avoid the difficulty and downtime of making a change. As a result, having the ability to change attachments easily not only makes the job safer and faster for the operator, but it also makes the job more efficient and effective due to the increased frequency of use of the correct excavator attachment.
[0010] There are, however, situations in which the use of a quick change coupler 164 is not advantageous. For example, in digging and ripping applications, where the shortest tip radius is often desirous, using a quick change coupler may not be the best alternative because the coupler increases the tip radius, thus reducing the overall breakout force of the machine, e.g., use of a quick connect coupler can reduce breakout force by between 10% and 15%. Similarly, in other dig-and-load and lifting situations, a quick connect coupler 164 adds significant weight at the end of the stick 124 , which decreases the payload that could otherwise be lifted safely. In addition, repeated lifting and lowering of a quick connect coupler increases fuel consumption and slows the cycle time of the digging operation, e.g. due to the extra weight. For example, a typical quick change coupler sized for use with 80 mm attachment pins weighs almost 1,000 pounds.
[0011] Hydraulic versions of pin-grabber couplers, e.g. as compared to mechanical versions, allow attachment changes to be made by an operator while remaining in the cab. However, the additional hydraulic valve and hydraulic plumbing of these couplers increases their complexity. These couplers and their plumbing components are also expensive, and introduce another possible source for contaminants in the hydraulic system. By way of example only, a typical hydraulic coupler for an excavator with 80 mm attachment pins may cost may cost as much as $8,000, not including the hydraulic kit, which can add another $4,000. The cost of a typical mechanical version of a pin-grabber coupler is, e.g., approximately $6,000.
SUMMARY
[0012] According to one aspect of the disclosure, an excavator attachment alignment tool comprises: a first alignment tool body portion and a cooperating second alignment tool body portion, the first and second cooperating alignment tool body portions mounted to a cross tube; the cross tube defining an alignment tool axis; and the cooperating alignment tool body portions being moveable relative to the cross tube into engagement to define a tapering, lower hook portion having opposed, spaced surfaces to accommodate and support an engaged excavator attachment pin in a position parallel with the alignment tool axis, the tapering, lower hook portion being positionable for lifting engagement with the excavator attachment pin, a pair of axially aligned cylindrical bushings mounted to opposed surfaces of the cooperating alignment tool body portions in alignment with the alignment tool axis, the cross tube engaged with and extending generally between the axially aligned cylindrical bushings; wherein, spacing of the cooperating alignment tool body portions, with the cylindrical bushings mounted thereto, is fixedly adjustable along the alignment tool axis for accommodating a width of an associated excavator link or excavator stick to which an excavator attachment is to be attached or to be removed; and wherein, the pair of cooperating alignment tool body portions is mounted in a manner to resist independent rotation of either of the pair of alignment tool body portions.
[0013] In preferred implementations of this aspect of the disclosure, at least one end of the cross tube is fixedly attached to a body portion of the pair of cooperating alignment tool body portions. The spacing of the cooperating first and second alignment tool body portions defines a first width between opposed inner surfaces of the cooperating first and second alignment tool body portions equal to a second width of the cooperating first and second alignment tool body portions at the lower hook portion. The excavator attachment alignment tool further comprises at least one member for locking axial positioning of at least one alignment tool body portion of the pair of cooperating alignment tool body portions relative to the cross tube. The member for locking axial position of the at least one alignment tool body portion is a locking collar. The opposed cylindrical bushings are sized for engagement within openings at opposite ends of an excavator stick boss or at opposite ends of an excavator link boss. Preferably, the excavator attachment alignment further comprises a pair of sleeve bushings, each sleeve bushing having an inner surface of diameter sized to be received over an outer surface of one of the cylindrical bushings in supporting engagement, and each sleeve bushing having an outer surface of diameter selected to be received within the openings at opposite ends of the excavator stick boss or at opposite ends of the excavator link boss in supporting engagement, thereby to accommodate use of the excavator attachment alignment tool with excavators having openings at opposite ends of the excavator stick boss or at opposite ends of the excavator link boss of a relatively greater diameters compared to the cylindrical bushings. The cooperating alignment tool body portions further comprise one or more guide plates mounted for sliding interengagement between the alignment tool body portions in a manner to resist independent rotation of either alignment tool body portion. The alignment tool body portions and the cross tube define cooperating interengageable structure for resisting independent rotation of either body portion. The lower hook portion is tapered toward the tip. With the excavator alignment tool engaged within the openings at opposite ends of the excavator stick boss or at opposite ends of the excavator link boss, and with an excavator attachment suspended by the hook portion of the excavator attachment alignment tool engaged with an excavator attachment pin having an excavator attachment pin axis, the excavator alignment tool axis and the excavator attachment pin axis engaged by the lower hook portion are disposed parallel to each other and disposed in alignment with the center of gravity of the suspended excavator attachment.
[0014] According to another aspect of the disclosure, an excavator attachment alignment tool is configured and arranged, when in use, to accommodate and support an engaged excavator attachment pin, to hold the excavator attachment pin with its axis parallel to an excavator linkage pin axis, and to hold an attachment longitudinal center plane co-planar with a linkage stick longitudinal center plane.
[0015] In preferred implementations of this aspect of the disclosure, the excavator attachment alignment tool, with an excavator attachment suspended from the alignment tool, the attachment pin axis and the excavator linkage pin axis are parallel, and define a second lateral plane that includes the center of gravity of the excavator attachment, thereby relieving radially-directed forces impeding insertion and removal of the connecting excavator attachment linkage pins and pin locking bolts.
[0016] According to still another aspect of the disclosure, a method for mounting and dismounting an excavator attachment using an excavator attachment alignment tool of the disclosure comprises the steps of: with an excavator machine running, lifting a presently mounted excavator attachment off the ground; extending or retracting a bucket cylinder to position the presently mounted excavator attachment with its center of gravity directly below a stick pivot; with the excavator attachment link pin now under little or no pressure, unbolting and pushing the link pin from the excavator link bore; swinging the link out of the way and inserting the attachment link pin back into the link bore of the first excavator attachment with no link; connecting the upper end of the excavator attachment alignment tool into one end of the link; positioning a lower hook portion of the excavator attachment alignment tool to generally encircle the first excavator attachment link pin; securing the excavator attachment alignment tool together with a proper width matching the width of the link; retracting the bucket cylinder to the first excavator attachment until its center of gravity is positioned directly below the link, with the excavator attachment link pin now being parallel to the excavator link pin bore, and the attachment center plane being aligned with the link center plane, and with the link vertical; with the pin under no pressure, unbolting and disengaging the stick or hinge pin;
[0017] inserting the stick or hinge pin into the link pin bore of the second excavator attachment; lowering the boom and moving the stick outward to lower the first excavator attachment to the ground, and releasing the excavator attachment alignment tool from the attachment pin of the first excavator attachment, with the second excavator attachment link pin now being parallel to the excavator link pin bore and the second excavator attachment longitudinal center plane now being aligned with the longitudinal excavator link center plane; engaging the excavator attachment alignment tool lower portion with the link pin of the second excavator attachment, and lifting the boom so that the second excavator attachment hangs freely; retracting the bucket cylinder so that the stick bosses of the second excavator attachment are positioned near the stick end; engaging the attachment pin into the bosses of the second excavator attachment and the stick boss by swinging or rocking the second excavator attachment into an easy insertion position, and bolting the attachment pin into place; extending the bucket cylinder so that the excavator attachment alignment tool is released from the link pin and the link boss is close to the second attachment link boss; removing the excavator attachment alignment tool; and inserting the link pin by swinging the excavator attachment fore and aft by hand, inserting the pin locking bolts, and securing the nut.
[0018] The excavator attachment alignment tool of this disclosure allows the excavator or backhoe operator to change excavator attachments without the use of a quick change coupler, and without having to deal with the difficulty of aligning linkage pins and pin locking bolts, and the associated heavy pounding required for placement and removal of stick and link pins.
[0019] The excavator attachment alignment tool of this disclosure also allows the operator to change excavator attachments without the cost, use and weight a quick change coupler, and without having to deal with heavy pin pounding and the difficult task of aligning the stick and link pins with locking collar cross bore segments for securement with threaded cross bolts and nuts.
[0020] The excavator attachment alignment tool of this disclosure allows the operator to employ a simplified method for removing an excavator attachment, and then mounting a new excavator attachment, regardless of the position or the flatness of the surrounding ground surface.
[0021] Changes of excavator attachments or tools can be completed with the excavator attachment alignment tool of this disclosure without the difficulties of hydraulic valve spool leakage drift mentioned above. Also, the excavator attachment is secured directly to the stick linkage, without an additional piece of equipment between stick linkage and the excavator attachment, so there is no reduction in breakout force. There is also no extra weight to reduce the amount of payload that can be lifted, or that can waste energy each time the boom is lifted.
[0022] Finally, by way of example only, the typical cost of an excavator attachment tool of this disclosure, e.g. for the 80 mm pin size, is approximately $1,060, which is less than about 20% of the cost of a mechanical quick change coupler.
[0023] The details of one or more implementations of the invention are set forth in the accompanying drawings and in the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0024] FIG. 1 is an exploded front view of the components of an excavator attachment alignment tool of the disclosure, including a first (left) alignment tool body portion, a second (right) alignment tool body portion, and a locking collar;
[0025] FIG. 2 is a right side view of the excavator attachment alignment tool assembly of FIG. 1 , with a hook portion formed in the lower region; and
[0026] FIG. 3 is an exploded isometric view of the components of the excavator attachment alignment tool of FIG. 1 .
[0027] FIG. 4 is an exploded isometric view of the components of an excavator attachment, in this case a bucket, being supported by the excavator attachment alignment tool of FIG. 1 , suspended from the excavator link boss. The stick is shown unattached, with the stick pin removed. For purposes of comparison and understanding, a second excavator attachment alignment tool of the disclosure is shown in dashed line, with its components (first (left) alignment tool body portion, second (right) alignment tool body portion, and locking collar) in unattached, exploded isometric view position.
[0028] FIG. 5 is a front view of excavator attachment of FIG. 4 , hanging from the hook portion of an excavator attachment alignment tool of the disclosure, suspended from the excavator link.
[0029] FIG. 6 is a left side view of the excavator stick and linkage, with the link pivot disconnected, and the excavator attachment (a bucket) hanging from the stick pivot, with the bucket center of gravity directly below the stick pivot.
[0030] FIG. 7 is a left side view of the excavator stick and linkage, with the stick pivot unattached, and the excavator attachment (the bucket) hanging from the hook portion of the excavator attachment alignment tool of the disclosure connected to the link pivot, with the bucket center of gravity directly below the link pivot, and in alignment with the excavator attachment pin axis.
[0031] FIG. 8 is a left side view of the excavator stick and linkage, with the stick pivot unattached, and an excavator attachment (a ripper) hanging from the hook portion of an excavator attachment alignment tool of the disclosure connected to the link pivot, with the ripper center of gravity directly below the link pivot, and in alignment with the excavator attachment pin axis
[0032] FIG. 9 is a left side view of the excavator stick and linkage with the link unattached and the excavator attachment (the ripper) hanging from the stick pivot with the ripper center of gravity directly below the stick pivot.
[0033] FIG. 10 is an exploded front view of the components of an excavator attachment alignment tool of the disclosure with diameter adjustment bushings; and FIG. 11 is a right side view of the excavator attachment alignment tool assembly of FIG. 10 with a hook portion formed in the lower region.
[0034] FIG. 12A is a prospective view of a hydraulic excavator with an excavator attachment arrangement fitted, e.g., with a multi-shank ripper excavation attachment, and FIG. 12B is prospective view of a hydraulic excavator fitted with a quick connect coupler, to which is mounted, e.g., a multi-shank ripper excavation attachment, all conventional and known in the prior art.
[0035] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0036] Referring to FIGS. 1, 2 and 3 , an excavator attachment alignment tool 10 of the present disclosure consists of a first (or left) body portion 12 and second (or right) body portion 14 . A first cylindrical bushing 18 is mounted to an inner surface 13 of the first body portion 12 , with the cylindrical bushing 18 defining a pivot bore 19 . A second cylindrical bushing 22 is mounted to an opposed inner surface 15 of the second body portion 14 , with the cylindrical bushing 22 defining a pivot bore 23 . In this implementation, a cross tube 20 is secured, e.g. by welding, in the pivot bore 19 of cylindrical bushing 18 .
[0037] The excavator attachment alignment tool 10 is assembled by sliding the free end 21 of cross tube 20 extending from the first body portion 12 through the pivot bore 23 of the cylindrical bushing 22 mounted to the opposed inner surface of the second body portion 14 . A locking collar 26 is then slid onto the external exposed end 21 ( FIG. 5 ) of cross tube 20 . The locking collar 26 (which may be a commercially available lock ring) is spring loaded and provides a locking function that resists axial movement of the second body portion 14 outwardly along the exposed end of the cross tube or shaft 20 when the locking collar 26 is engaged.
[0038] The first and second body portions 12 , 14 are then slid together along the cross tube 20 . When adjustably assembled, the bottom regions 1 , 2 of the respective first and second body portions 12 , 14 of the alignment tool 10 cooperatively form a lower hook portion 32 , and guide plates 34 , 36 welded to rear (outer) surface 11 of the first body portion 12 serve to engage and hold the first and second body portions 12 , 14 when the two body portions are slid together, thereby resisting relative rotation.
[0039] Commercially, different brands of excavator attachments having a common pin diameters may typically may have different link widths. The sliding adjustable inter-engagement of the first and second body portions 12 , 14 of the excavator attachment alignment tool 10 of this disclosure thus permits positioning of the engaged body portions at variable combined width dimensions, W, thereby to accommodate a wide range of linkage widths, while also providing a hook of the proper width dimension.
[0040] Referring still to FIGS. 1, 2 and 3 , the cross tube 20 of the excavator attachment alignment tool 10 of the disclosure is welded to the first or left side body segment 12 . A relatively larger diameter cylindrical bushing 18 mounted on the tube has a diameter corresponding to the diameter of the smallest pin diameter in the excavator size class. The second or right side body portion 14 has a welded bushing 22 of similar, relatively large outside diameter. An excavator attachment alignment tool 10 of the disclosure is dimensioned for use with a pin having, e.g., an 80mm diameter for the class size shown, but can be adapted for use with excavator attachments having link pins and stick or hinge pins of other, relatively larger dimension.
[0041] Referring briefly to FIGS. 10 and 11 , by way of example only, adjustment bushings 42 , 44 , each having a wall of thickness, T, e.g. 5 mm, and an outside diameter, OD, e.g. 90 mm, can be slipped over the 80 mm welded bushings 18 , 22 , respectively, at each end of the cross tube 20 , thereby to adjust the excavator attachment alignment tool 10 for use with a 90 mm size class machine (i.e., with an excavator attachment with link and stick or hinge pins having a 90 mm outer diameter). As a result, depending on the class size of the excavator, the excavator attachment alignment tool 10 of the disclosure can be quickly adapted for use, e.g., with 80 mm, 90 mm, 100 mm and 110 mm diameter link and stick or hinge pins, by simply sliding on adjustment bushings of the appropriate dimension. The inside radius, R, of the lower hook portion 32 typically corresponds to the smallest diameter pin size, i.e. in the case shown, 80 mm, at its base, but the opposed hook wall surfaces thereabove flare out to a relatively larger distance, D, apart, i.e. relatively greater than 2 R, thereby to accommodate and align link and stick or hinge pins 132 , 134 of relatively greater diameter.
[0042] The width, W L , at the lower end portion of the hook is the same as the width, W, between the opposed inner surfaces 11 , 13 inside of the upper portions of the vertical plates (see, e.g., FIG. 5 ). When the alignment tool 10 is in use, the inner opposed surfaces 13 , 15 of the respect first and second body portions 12 , 14 are tightly engaged at opposed side surfaces of the link (or stick). The hook shape is such that an excavator attachment is easily “hooked” or picked up by engaging the lower hook portion 32 of the excavator attachment alignment tool 10 underneath an excavator attachment pin 132 or 134 . The excavator attachment pin slides easily into the curve of the hook 32 of the excavator attachment alignment tool 10 , and then aligns the excavator attachment so that the axis of the excavator attachment pin is axially aligned with the axis of the cross tube 20 of the excavator attachment alignment tool, and thus axially aligned with the link pin bore 174 of the excavator link 142 ( FIG. 6 ). In this manner, the excavator attachment pin is arranged parallel to the link pin bore and the excavator attachment is aligned side-to-side in position for engagement and mounting to the excavator arm such that the excavator attachment longitudinal center plane is disposed in alignment with the longitudinal link center plane. As a result, the procedure for changing from a first excavator attachment (e.g., a Multi-Ripper bucket 50 , FIGS. 4, 6 and 7 ) to a second excavator attachment (e.g., a non-bucket Multi-Ripper 52 , FIGS. 8 and 9 ) is relatively simply achieved.
[0043] As described above, the excavator attachment alignment tool 10 consists of a first or right portion 12 and a second or left portion 14 , with an upper end configured for secure engagement with and mounting upon the stick boss 170 or the link boss 174 of the excavator arm in the manner of the stick or hinge pin 132 or the link pin 134 . The lower end portion of the alignment tool 10 has the form of a tapered hook 32 that assists in the dismounting (i.e., “dropping off”) of the “old” excavator attachment already in use, and/or the mounting (i.e., “picking up”) of a “new” excavator attachment. The excavator attachment alignment tool 10 allows the operator to change the stick or hinge pin 132 and link pin 134 , one at a time, creating a sequence of conditions for each pin such that the pin force is low, and the excavator attachment is off the ground. The pin forces are low at the time of each pin insertion or removal because the alignment tool 10 allows the center of gravity (CG) of the excavator attachment to be in a position that relieves the force from the joint. Since the pin placement operations occur while there is a reduced level of force or load upon the link pin 134 or stick or hinge pin 132 , the pin can be pushed in or removed relatively more easily (i.e., with relatively less force), and it is easier (again, with less force) to rotate the pins in order to align the cross bolt hole segment of the pin 132 , 134 with the cross bolt hole segments of the respective locking collars 156 , 160 for insertion of the locking bolts 150 .
[0044] Also, as discussed above, a single model of the excavator attachment alignment tool 10 of the disclosure can be adapted for use across a range of several different excavator attachment pin diameters. For example, an excavator attachment alignment tool 10 of the disclosure can be used with a range of different excavator attachments, as long as the excavator attachment pin diameter is within the indicated range. Many excavators within a single size class have excavator attachments pins of a common diameter.
[0045] For example, excavator attachments such as Hitachi EX200, Cat 320, Case CX160 or CX210, John Deere 200, Komatsu PC200, and Linkbelt LX160 all have 80 mm pins for the excavator attachment linkage hook-up. As a result, for all of these excavator machines, a single model of the excavator attachment alignment tool 10 of this disclosure can be used without additional components. In addition, excavator machines having 90 mm, 100 mm or 110 mm diameter excavator attachment pins can also be adapted for use with the same excavator attachment alignment tool by the addition of sleeves or bushings of appropriately different diameters. Therefore, one model size of the excavator attachment alignment tool 10 of the disclosure can be used for excavator attachments with pin sizes from 80 mm up to 110 mm (i.e., the pin diameter range encompassing all mid-sized 40,000 to 110,000 pound excavator machine class sizes). A smaller model of the excavator attachment alignment tool of the disclosure, with sleeves having different diameters can accommodate 45 mm, 56 mm, 66 mm and 70 mm excavator attachment pins, e.g. as found in smaller excavators and backhoes in the 11,000 to 40,000 pound range). As a result, only two models of the excavator attachment alignment tool 10 of this disclosure are sufficient to cover excavators and backhoes from 11,000 pounds up to larger excavators weighing 110,000 pounds. By way of example only, the larger size excavator attachment alignment tool weighs approximately 55 pounds, while the smaller excavator attachment alignment tool weighs approximately 35 pounds.
[0046] Mini-excavators and backhoes that have excavator attachments with pin diameters less than 45 mm are typically easier to change, e.g. due to the relatively reduced weight of the excavator attachments. As a result, an excavator attachment alignment tool is less likely to be needed in that size range. Larger excavators having attachment pins with diameters greater than 110 mm would generally require an excavator attachment alignment tool that would be too heavy to lift manually.
[0047] We will now describe a typical procedure for use of the excavator attachment alignment tool 10 of the disclosure with one operator, and one helper for dismounting and mounting an excavator attachment:
[0048] Step 1 : With the excavator machine 100 running, and the operator in the cab 118 to operate the excavator machine hydraulic controls, the presently mounted excavator attachment (e.g. an excavator bucket 50 ) is lifted about a foot off the ground. The bucket cylinder 130 is then extended or retracted so that the center of gravity (CG) of the currently mounted excavator attachment is directly below the stick pivot 132 .
[0049] Step 2 : With the excavator attachment link pin 134 now under no pressure, the helper unbolts and pushes the link pin 134 out of the excavator link bore 170 . The link 142 is next swung out of the way, and the attachment link pin 134 is inserted back into the link bore 170 of the first excavator attachment 50 with no link (see, e.g., FIG. 6 ).
[0050] Step 3 : The helper slides free end 21 of the cross tube 20 and then the cylindrical bushing 18 of the first or left body portion 12 of the excavator attachment alignment tool 10 into one end of the link 174 , and then slides the second or right portion 14 of the excavator attachment alignment tool onto the free end 21 of the cross tube 20 and into the opposite end of the link boss 174 , e.g. as shown FIG. 4 ). The helper positions the lower hook portion 32 of the excavator attachment alignment tool 10 to generally encircle the first excavator attachment (link) pin 134 , and then slides the locking collar 26 onto the end 21 of the cross tube 20 , thereby to secure the first and second hook portions 12 , 14 of the excavator attachment alignment tool 10 together with proper width, W, matching the width of the link 142 (see FIG. 5 ).
[0051] Step 4 : The operator next retracts the bucket cylinder 130 , thus lifting the first excavator attachment 50 until the center of gravity, CG, of the excavator attachment is positioned directly below the link 134 , and the link 142 is vertical. Then, with the pin 134 under no pressure (see FIG. 7 ), the helper can easily unbolt and disengage the stick or hinge pin 132 .
[0052] Step 5 : The helper then puts the stick or hinge pin 132 into the link pin bore 170 of the second excavator attachment (e.g., a ripper 52 ).
[0053] Step 6 : The operator then lowers the boom 122 and moves the stick 124 outward to lower the first excavator attachment 50 to the ground and unhook the excavator attachment alignment tool 10 from the attachment pin 132 of the first excavator attachment 50 .
[0054] Step 7 : The operator then engages the excavator attachment alignment tool 10 lower hook portion 32 with the link pin 132 of the second excavator attachment 52 , and lifts the boom 122 so that the second excavator attachment is hanging freely. (The second excavator attachment pin 134 is now parallel and centered, e.g., see FIG. 8 .) The operator then retracts the bucket cylinder 130 so that the stick bosses 170 of the second excavator attachment 52 are positioned near the stick end 124
[0055] Step 8 : The helper then engages the attachment pin 134 into the bosses 172 of the second excavator attachment 52 and the stick boss 170 by swinging or rocking the second excavator attachment 52 (with his hand), into an easy insertion position. He then bolts the attachment pin 134 into place.
[0056] Step 9 : The operator then extends the bucket cylinder 130 so that the excavator attachment alignment tool 10 is unhooked from the link pin 134 and the link boss 174 is close to the second attachment link boss 176 and the helper removes the excavator attachment alignment tool 52 (see FIG. 9 )
[0057] Step 10 : The helper finally inserts the link pin 134 by swinging the excavator attachment 52 fore and aft with his hand, inserts the pin locking bolts 150 , and secures the nut 152 . The procedure is then complete!
[0058] The entire process described above can also be completed by the operator working alone; however, this would require that the operator make several trips in and out of the cab. The excavator attachment alignment tool 10 of the disclosure works easily because when the first and second portions 12 , 14 of the excavator attachment alignment tool 10 are pushed together on the link 142 (or the stick 124 ), the inner diameter of the hook 32 is the same width or diameter as the link pin 134 or stick or hinge pin 132 ), thus automatically positioning the excavator attachment 50 or 52 with the attachment pins 132 , 134 disposed parallel to each other, and the excavator attachment is centered properly on the machine, with the longitudinal center plane of the excavator attachment is in alignment with the longitudinal center plane of the link 142 (or the stick 124 ). Due to this positioning of the center of gravity of the excavator attachment, the excavator attachment alignment tool 10 allows the pins 132 , 134 to be relieved of pressure, thus allowing insertion, removal, and rotational alignment of the pin bolts 150 to be easier.
[0059] Also, referring to FIG. 7 , the excavator attachment alignment tool 10 is configured and arranged, when in use to accommodate and support an engaged excavator attachment pin (link pin or pivot 134 ), to hold the excavator attachment pin with its axis parallel to an axis of the excavator linkage pin (cross tube 23 ), with an attachment lateral center plane including the excavator attachment pin axis disposed co-planar with a linkage stick lateral center plane including the excavator linkage pin axis.
[0060] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the excavator attachment alignment tool 10 can be used on the stick pivot 170 , as well as on a link pivot 174 .
[0061] Also, other means for keeping the alignment tool body portions 12 , 14 from rotating can be employed. For example, the cross tube 20 may be splined with mating grooves inside the opposite halves, thereby to resist relative rotation. The excavator attachment alignment tool hook can be manufactured from round stock bars, rather than plates. In use, the excavator attachments alignment tool can be reversed, e.g., so that the cross tube 20 is connected to the excavator attachment and the alignment tool hook portions 12 , 14 straddle the link pin 134 and engage onto the ends of the attachment pin in the link bore.
[0062] Accordingly, other embodiments are within the scope of the following claims. | An excavator attachment alignment tool has cooperating tool body portions mounted to a cross tube defining an axis. The tool body portions are moveable relative to the cross tube to define a lower hook portion having surfaces to accommodate and support an engaged excavator attachment pin parallel with the tool axis, with the lower hook portion positionable for lifting engagement with the excavator attachment pin. Aligned cylindrical bushings are mounted to opposed surfaces of the body portions in alignment with the tool axis, with the cross tube engaged and extending generally between the bushings, with spacing of the cooperating tool body portions fixedly adjustable along the tool axis for accommodating a width of an associated excavator link or stick to which an excavator attachment is to be attached or removed; and wherein the tool body portions are mounted in a manner to resist independent rotation of either body portion. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of our copending application Ser. No. 241,847 filed April 6, 1972, entitled "Pyridone Derivatives" now U.S. Pat. 3,821,235.
BACKGROUND OF THE INVENTION
The present invention relates to new anti-inflammatory and analgestic compositions.
There are known various anit-inflammatory agents, e.g. certain steroids (cortisone and its derivatives); acetyl salicylic acid (hereinafter called aspirin), butazolidin or indometacin. However, most of these known agents have unpleasant side effects, e.g. they cause ulcers.
It has thus been desirable to find compounds, which are useful anti-inflammatory agents, which are substantially as effective as the known anti-inflammatory agents but which have less unpleasant side effects.
M. Conrad and M. Guthzeit (Ber., 19(1886) and Ber., 20, 154 (1887) describe the preparation of 2,6-dimethyl-3,5-dicarboethoxy-4-pyridone, 2,6-dimethyl-3,5-dicarboethoxy-N-phenyl-4-pyridone, 2,6-dimethyl-3,5-dicarboethoxy-N-methyl-4-pyridone and 2,6-dimethyl-3,5-dicarboethoxy-N-acetyl-4-pyridone.
V. Ettel and J. Hebky, Coll. Czech.Chem.Com., 15, 639 (1950) and J. Hebky, Coll. Czech.Chem.Com., 16, 348 (1951) describe the synthesis of some of the same compounds as well as:
2,6-Dimethyl-3,5-dicarboethoxy-N-(p-hydroxyphenyl)-4-pyridone and its diacid;
2,6-Dimethyl-3,5-dicarboethoxy-N-(m-hydroxyphenyl)-4-pyridone and its diacid;
2,6-Dimethyl-3,5-dicarboethoxy-N-(4'-hydroxy-3',5'-dimethoxy phenyl)-4-pyridone and its diacid;
2,6-dimethyl-3,5-dicarboethoxy-N-(p-acetamidophenyl)-4-pyridone and its diacid;
1,4-bis-N,N'-(2',6'-dimethyl-3',5'-dicarboethoxy-4'-pyridone)-phenylene and its tetracid;
2,6-dimethyl-3,5-dicarboethoxy-N-(p-Iodophenyl)-4-pyridone and its diacid;
2,6-dimethyl-3,5-dicarboethoxy-N-(2',4'-Diiodophenyl)-4-pyridone and its diacid;
2,6-dimethyl-3,5-dicarboxy-N-(4'-hydroxy-3',5'-diiodophenyl)-4-pyridone
2,6-dimethyl-3,5-dicarboxy-N-(3'-hydroxy-2',4',6'-triiodophenyl)-4-pyridone.
Ettel & Hebky studied these compounds because of their interest in a novel X-Ray contrast agent for a similar use as the known diethanolamine salt of 3,5-diiodo-4-pyridone-N-acetic acid. They thus prepared and tested salts of the various above mentioned 2,6-dimethyl-N-(various Iodophenyl)-4-pyridone-3,5- dicarboxylic acids as X-Ray contrast agents.
We have now surprisingly found that certain esters of 2,6-dimethyl-N-substituted-4-pyridone-3,5-dicarboxylic acid have good anti-inflammatory properties substantially without having the unpleasant side effects of the known anti-inflammatory agents. Moreover, some of same pyridones have useful analgetic properties and some have beta-blocking properties. The free acids show substantially no activity while if the nitrogen carries no substituent the compounds are neurotoxic.
SUMMARY OF THE INVENTION
The present invention thus consists in pharmaceutical compositions comprising as active substance a pyridone derivative of the general formula I ##SPC1##
in which R 1 and R 2 stand for the same or different substituted or unsubstituted alkyl, alkylene, cycloalkyl or benzyl radicals and R stands for a phenyl radical which may be optionally substituted with one or more substituents selected from the group comprising alkyl, alkoxy, nitro, chloro, fluoro and dialkylamino radicals which may be the same or different.
Pyridones of general formula I comprise also bis-pyridones of general formula II ##SPC2##
in which R 1 and R 2 have the same meaning as above and R 3 stands for hydrogen or for one or more substituents selected from the group comprising alkyl, alkoxy, nitro, chloro, fluoro, and substituted amino radicals which may be the same or different.
Many of the compounds of general formula I are new compounds. The present invention thus consists also in pyridone derivatives of general formula I wherein R 1 and R 2 have the same meaning as above and R stands for a phenyl radical substituted with one or more substituents selected from the group comprising alkyl, alkoxy, nitro, chloro, fluoro and dialkylamino radicals which may be the same or different.
The compounds of the present invention may be prepared by various suitable methods. A suitable process consists in reacting a pyrone of general formula III ##SPC3##
with an amine of general formula IV
r -- nh.sub.2
in which R, R 1 and R 2 have the same meaning as above. This reaction is preferably performed in acetic acid at elevated temperatures, e.g. 100°-130°C.
Compounds of general formula III may be prepared, for example, as described by Conrad and Guthzeit mentioned above.
In case that R 1 should be different from methyl or ethyl, an appropriate pyridone having R 1 equal R 2 being ethyl (or methyl) may be transesterified by boiling with an excess of the appropriate alcohol in the presence of an acid as catalyst and the lower boiling alcohol (methanol or ethanol) is removed by distillation. By this process only one group is transesterified.
Should both R 1 and R 2 have to be different from ethyl, the carboethoxy groups of the pyridone may be subjected to saponification and the compound obtained is esterified with the desired alcohol. Said esterification is preferably performed by first preparing the acid chloride, e.g. by reacting the 2,6-dimethyl-3,5-dicarboxy N-phenyl-4-pyridone with thionyl chloride in benzene and reacting thereafter the acid chloride with the desired alcohol.
The new compositions according to the present invention are preferably prescribed in the form of tablets, capsules, ampules, suppositoria, ointments, tinctures or solutions, said preparations being prepared in a conventional manner, i.e. by the addition of suitable binders, extenders, carriers, emulsifyers, solvents, other suitable therapeutic compounds and the like.
Compounds of general formula I showed anti-inflammatory properties when tested in the carrageenin induced oedema test on the hind paw of rats or in the cotton pellet granuloma test in rats. At present we found the 4-alkoxyphenyl derivatives to be the most active ones.
Significant anti-inflammatory activity and a good dose response was found at dosages between 50 mg/kg body weight and 200 mg/kg when administered orally or intraperitoneally.
Moreover, compounds of the pyridone derivatives of general formula I show a low ulcerogenic index at the effective anti-inflammatory dosage.
Some of the compounds demonstrated analgetic properties estimated by measuring the pain threshold in rats by the method of Randall and Selitto.
The toxicity of the tested compounds was quite low.
The present invention thus consists also in a method for the treatment of inflammations and/or for the relief of pain with a therapeutic dosage of a pyridone derivative of general formula I or with a composition containing same.
DESCRIPTION OF PREFERRED EMBODIMENTS
The following examples are given to further illustrate, but not restrict, the present invention.
EXAMPLE 1
2,6-dimethyl-3,5-dicarboethoxy-N-phenyl-4-pyridone was prepared cording to Conrad and Guthzeit (M. Conrad and M. Guthzeit, Chem. Ber., 19, 19-26, (1886)), by reacting 2,6-dimethyl-3,5-dicarboethoxy-4-pyrone (said compound will be called hereinafter "the pyrone") and aniline in acetic acid. (m.p. 170°C).
The compound has a good inhibitory effect on the development of Carrageenin induced Oedema in rats at a dose of 50 mg/kg and very good activity at the doses of 100 and 200 mg/kg, via oral or i.p. administration.
In doses of 100 mg/kg and 200 mg/kg the compound inhibited the cotton pellet granuloma formation in rats. The activity was greatly reduced with adrenolectromised rats were used in the experiments. a low ulceration index was recorded at doses between 50 mg/kg to 200 mg/kg in comparison with aspirin and indomethacin.
EXAMPLE 2
6.7 g. of o-toluidine were added to a solution of 8.5 g. of the pyrone in 60 ml. of glacial acetic acid. The mixture was stirred and heated at 110° for 1 hour. The mixture was then cooled and poured into 100 g. of crushed ice. The mixture obtained was neutralised with concentrated ammonia to pH 6 and the precipitate was filtered off, washed with water and dried yielding 8 g. of 2,6-dimethyl-3,5-dicarboethoxy-N-(2'-methyl-phenyl)-4-pyridone; m.p. 178°C.
The compound has a good inhibitory effect on the development of Carrageenin induced Oedema in rats at doses of 100 mg/kg and very good effects at 200 mg/kg. A very low ulceration index was recorded at a dose of 200 mg/kg in comparison to aspirin and indomethacin.
EXAMPLE 3
1.1 g. of 3-chloro aniline and 2 g. of the pyrone were dissolved in 10 ml. of glacial acetic acid. The mixture was stirred and heated for 15 minutes to 110°, then cooled and poured into 50 g. of ice and was thereafter neutralised with concentrated ammonia to pH 7. The precipitate was filtered off by suction, washed with water and dried to yield 3 g. of crude 2,6-dimethyl-3,5-dicarboethoxy-N-(3'-chlorophenyl)- 4-pyridone; m.p. 204°-206°. After recrystallization from benzene the m.p. was 209-210°C.
At a dose of 200 mg/kg the compound exhibited moderate anti-inflammatory effect in the Carrageenin induced oedema.
In the same manner were prepared:
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-chlorophenyl)-4-pyridone m.p. 129°:
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-fluorophenyl)-4-pyridone m.p. 169°:
2,6-dimethyl-3,5-dicarboethoxy-N-(2'-fluorophenyl)-4-pyridone m.p. 112°:
2,6-dimethyl-3,5-dicarboethoxy-N-(3'-fluorophenyl)-4-pyridone m.p. 212°:
EXAMPLE 4
2 g. of pyrone were reacted with 1.5 g. of 4-n-butoxyaniline in the same manner as described in Example 2 to yield 3 g. of 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-n-butoxyphenyl)-4-pyridone; m.p. 134°-5°C.
The compound has a good inhibitory effect on the development of Carrogeenin induced Oedema in rats at a dose of 100 mg/kg and a very good effect at a dose of 200 mg/kg. The compound also inhibited granuloma formation in intact and adrenalectomized rats at the doses of 100 mg/kg and 200 mg/kg.
A low ulcerogenic index was recorded at the doses described above. At a dose of 200 mg/kg the compound had a good effect on adjuvant arthritis in rats, as compared to indomethacin. A good analgesic activity was observed at a dose of 200 mg/kg as compared to aminopyrine.
The following compounds were prepared in the same manner:
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-ethoxyphenyl)-4-pyridone; m.p. 165°
2,6-dimethyl-3,5-dicarboethoxy-N-(4' methoxyphenyl)-4-pyridone; m.p. 159-160°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-isobuthoxy-phenyl)4-pyridone; m.p. 110°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-isopentyloxyphenyl)4-pyridone; m.p. 168°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-heptyloxyphenyl)4-pyridone; m.p. 102°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-octyloxyphenyl)4-pyridone; m.p. 86°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-tetradecyloxyphenyl)-4-pyridone; m.p. 87°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-octadecyloxyphenyl)4-pyridone; m.p. 90°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-decyloxyphenyl)4-pyridone; m.p. 87°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-cyclohexyloxyphenyl)4-pyridone; m.p. 170°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-heptadecyloxyphenyl)4-pyridone; m.p. 85°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-pentyloxyphenyl)4-pyridone; m.p. 92°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'(3"hexyloxy)phenyl)4-pyridone; m.p. 145°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'-pentadecyloxyphenyl)4-pyridone; m.p. 95°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'(4"heptyloxy)phenyl)4-pyridone; m.p. 116°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'(2"heptyloxy)phenyl)4-pyridone; m.p. 90°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'(4"octyloxy)phenyl)4-pyridone; m.p. 104°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'(3"pentyloxy)phenyl)4-pyridone; m.p. 172°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'propoxyphenyl)4-pyridone; m.p. 122°
2,6-dimethyl-3,5-dicarboethoxy-N-(4'hexyloxyphenyl)4-pyridone; m.p. 104°
2,6-dimethyl-3,5-dicarboethoxy-N-(2'4'-dimethoxy)4-pyridone; m.p. 178°
In the Carrogeenin induced Oedema in the rat the compounds described above showed good to very good activity at a dose of 200 mg/kg and some have moderate to good angesic activity at the same dose.
EXAMPLE 5
1.25 g. of the pyrone was reacted with 0.4 g. of p-toluidine in the same manner as described in Example 2 to yield 1.2 g. of 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-methylphenyl)-4-pyridone; m.p. 110°.
At a dose of 200 mg/kg the compound showed moderate anti-inflammatory effect on the Carrageenin induced oedema in rats.
EXAMPLE 6
1.25 g. of the pyrone was reacted with 2.3 g. of dimethyl aniline in the same manner as described in Example 2 to yield 1.7 g. of 2,6-dimethyl-3,5-dicarboethoxy-N-(2',3'-dimethyl-phenyl)-4-pyridone; m.p. 100° (recrystallised from benzene petrol-ether 40°-60°C)
At a dose of 200 mg/kg the compound showed moderate anti-inflammatory effect on the Carrageenin induced oedema in rats.
EXAMPLE 7
2 g. of the pyrone and 1.1 g. of 4-nitroaniline were dissolved in 20 ml. of acetic acid and the mixture was stirred and heated to 110° for 24 hours. Thereafter the mixture was cooled and poured into 100 g. of crushed ice. The suspension was neutralised to pH 7 with concentrated ammonia and the crystals obtained were filtered off and dried.
Yield: 1.5 g. of 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-nitrophenyl)-4-pyridone; m.p. 195°.
At a dose of 200 mg/kg the compound showed good anti-inflammatory effect on the Carrageenin induced oedema in rats.
EXAMPLE 8
2 g. of the pyrone and 1.32 g. of p-dimethylamino aniline were dissolved in 20 ml. of acetic acid and the mixture was stirred and heated to 110° for 30 minutes. Then it was cooled, poured on 100 g. crushed ice and neutralised to pH 7 with concentrated ammonia. The oil that separated was extracted with chloroform. The obtained extracts were dried over magnesium sulphate and the chloroform was dissolved off in vacuo. The residue was crystallised from ethanol water to yield 1.5 g. of 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-dimethylaminophenyl)-4-pyridone; m.p. 140°.
At a dose of 200 mg/kg the compound showed weak anti-inflammatory effect on the Carrageenin induced oedema in rats.
EXAMPLE 9
2 g. of the pyrone were reacted with 1.32 g. of 4-diethyl amino aniline in the same manner as described in Example 8 to yield 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-diethylaminophenyl)-4-pyridone; m.p. 138°.
At a dose of 200 mg/kg the compound showed good anti-inflammatory effect on the Carrageenin induced oedema in rats.
EXAMPLE 10
4 g. of 2,6-dimethyl-3,5-dicarboethoxy-N-phenyl-4-pyridone (prepared as described in Example 1) were dissolved in 20 ml. of benzyl alcohol, 4 drops of concentrated H 2 SO 4 were added and the mixture was stirred and heated for 7 hours at 130°, at the same time distilling off the produce ethanol. The benzyl alcohol solution was washed with a saturated solution of sodium bicarbonate and the slurry was extracted several times with chloroform. The extracts were combined and dried over magnesium sulphate, and the chloroform was distilled off in vacuo. The oily residue was dissolved in 50 ml. of ether and 50 ml. of petrolether 40'-60° were added. After cooling in a dry ice-acetone bath and scratching, 2,5g. of 2,6-dimethyl-3-carboethoxy-5-carbobenzyloxy-N-phenyl-4-pyridone, m.p. 142° were obtained.
At a dose of 200 mg/kg the compound showed weak anti-inflammatory effect on the Carrageenin induced oedema in rats.
EXAMPLE 11
1.5 g. of 2,3-dimethyl-3,5-dicarboethoxy-N-phenyl-4-pyridone (prepared as described in Example 1) was dissolved in 45 ml. of butanol, 2 drops of concentrated sulfuric acid were added and the mixture was stirred and heated at 100° for seven hours, and the produced ethanol was distilled off simultaneously. The mixture was cooled, transferred into a separatory funnel and shaked with a saturated solution of sodium bicarbonate. The organic phase was separated and evaporated to dryness. The residue was crystallised from isopropanol to yield 0.5 g. of 2,6-dimethyl-3-carboethoxy-5-carbobutoxy-N-phenyl-4-pyridone; m.p. 110°.
At a dose of 200 mg/kg the compound showed moderate anti-inflammatory activity on the Carrageenin induced oedema in rats.
EXAMPLE 12
The tetra ethyl ester of phenylene-1,4-bis-N,N'-(2,6-dimethyl-3,5-dicarboxylic acid-4-pyridone) was prepared according to Ettel (V. Ettel and J. Hebky, Coll. Czech. Chem. Commun., 15, 639-651 (1950)) by reacting p-phenylene diamine with the pyrone in acetic acid.
The compound has a good inhibitory effect on the development of Carrageenin induced Oedema in rats at a dose of 100 mg/kg and very good effect at a dose of 200 mg/kg. The compound inhibited granuloma formation in intact and adrenalectomised rats at doses of 100 mg/kg and 200 mg/kg. Low ulcerogenic indexes was recorded at the doses described above as compared to indomethacin. A very good analgesic activity was observed at a dose of 200 mg/kg as compared to amino pyrine.
In a similar manner utilising as starting material the appropriate diamine the following compounds were prepared:
a. 1,4-bis-N,N'-(2,6-dimethyl-3,5-dicarboethoxy-4'-pyridone-N)-2-methyl-phenylene; m.p. 313°
b. 1,4-bis-N,N'-(2,6-dimethyl-3,5-dicarboethoxy-4'-pyridone-N)-2-methoxy-phenylene; m.p. 315°
c. 1,4-bis-N,N'-(2,6-dimethyl-3,5-dicarboethoxy-4'-pyridone-N)-2,5-dimethyl-phenylene; m.p. 320°
EXAMPLE 13
2,6-dimethyl-N-phenyl-4-pyridone-3,5-dicarboxylic acid was prepared according to Conrad and Guthzeit (M. Conrad and M. Guthzeit, Chem. Ber., 20, 154-163 (1887)).
A solution of 1 g. of the diacid and 1,23 g. of thionyl chloride in 50 ml. of benzene was refluxed for 4 hours. The solvent was removed in vacuo. To the residue were added 50 ml. of anhydrous methanol and the mixture was refluxed for 1 hour. The methanol was removed in vacuo, water was added and the acid solution was neutralised to pH 6.5. The material which had been precipitated was filtered off and dried in the air to yield 2,6-dimethyl-3,5-dicarbomethoxy-N-phenyl-4-pyridone; 88.5% yield; m.p. 215°.
EXAMPLE 14
A solution of 1 g 2,6-dimethyl-3,5-carboxy-N-phenyl-4-pyridone and 1.23 g. of thionyl chloride in 50 ml of benzene was refluxed for four hours. The solvent was removed in vacuo. To the residue were added 50 ml. of isopropyl alcohol and the mixture was refluxed for 1 hour. The solvent was removed in vacuo, water was added and the solution was neutralised to pH 6.5. The solid which precipitated was filtered off and dried in the air, to yield 2.5 g of 2,6-dimethyl3,5-dicarbo-isopropyloxy-N-phenyl-4-pyridone; m.p. 185°.
In the same way were prepared utilising the appropriate alcohols:
a. 2,6-dimethyl-3,5-dicarbo cyclohexyloxy-N-phenyl-4-pyridone; m.p. 80°.
b. 2,6-dimethyl-3,5-dicarbo (1'-propene)-yloxy-N-phenyl-4-pyridone;m.p. 140°,
c. 2,6-dimethyl-3,5-dicarbo isobutyloxy-N-phenyl-4-pyridone; m.p. 200°C
d. 2,6-dimethyl-3,5-dicarbo butyloxy-N-phenyl-4-pyridone; m.p.
EXAMPLE 15
Tablets of a pyridone can be prepared in the following manner: Blend together 400 g of 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-heptyloxy phenyl)-4-pyridone-(active compound) and 100 g lactose with starch paste (made of 25 g starch) dry in the oven at 45°C overnight. Pass the dry granulation through a No. 16 stainless steel screen. To the screened granulation add 2.7 g stearic acid and 50 g talcum(previously screened through a size 40 stainless steel screen) and compress to tablets.
In this way each tablet contains:
______________________________________Active compound 400 mgLactose 100 mgStarch 25 mgStearic acid 2.7 mgTalcum 50 mg______________________________________
EXAMPLE 16
Capsules of a pyridone can be prepared in the following manner: Blend well 400 g of 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-heptyloxyphenyl)4-pyridone (Active compound) and 200 g lactose and 60 g of Cabosil and fill into capsules.
Each capsule contains:
______________________________________Active compound 400 mgLactose 200 mgCabosil (Fumed silica ofCabot Corp.) 6 mg______________________________________
EXAMPLE 17
Tablets of a pyridone can also be prepared in the following manner: Blend 400 g of 2,6-dimethyl-2,5-dicarboethoxy-N-(4'-N-buthoxy phenyl) -4-pyridone (active compound) and 200 g of starch and make 1/2 inch slugs. Pass the slugs through a Fitz mill.
Dust on 1.5 g Mg stearate on the granulation and compress on a BB2, press into tablets using flat level edge 12 mm punches.
Each tablet contains:
______________________________________Active compound 400 mgStarch 200 mgMg stearate 1.5 mg______________________________________
EXAMPLE 18
Suppositories of a pyridone can be prepared as follows: Melt at 50°C 16 g of cocoa butter, add 40 mg of 2,6-dimethyl-2,5-dicarboethoxy-N-(4'-n-buthoxy phenyl)-4-pyridone, homogenize if necessary, pour into moulds and allow to congeal. Extrude suppositories and wrap.
EXAMPLE 19
Ointment of a pyridone can be prepared in the following manner: In 80 ml of boiling water dissolve 200 mg of methyl parabene and 50 mg of propyl parabene, cool to 70°C. In a separate container melt 10 g of cetostearyl alcohol, add 400 mg of 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-(3" pentyloxy)-phenyl)-4-pyridone (active compound) and heat to 70°C. Add the water phase into the oil phase with vigorous agitation. Continue agitation until temperature drops to 45°C. Allow mixture to cool to room temperature, and package into appropriate size tubes.
The formula thus obtained is:
______________________________________Active compound 0.4%ceto-stearyl alcohol 10%methyl parabene 0.2%propyl parabene 0.05%water quantity sufficient to 100%______________________________________
EXAMPLE 20
A suspension of a pyridone may be prepared in the following manner: Into 50 ml. of boiling water dissolve 200 mg of methyl parabene and 50 mg. of propyl parabene and then add with vigorous agitation carbomethylcellulose (CMC) (100 mg), vee gum (5 g)(Vee gum stands for magnesium aluminium silicate of Vanderbilt), sugar (30 g) and 70% solution of Sorbo (20g)(70%Sorbitol). Continue agitation until gums are fully hydrated. Dust on the 2,6-dimethyl-3,5-dicarboethoxy-N-(4'-3"-pentyloxy)-4-pyridone)-(active compound) (2 g), mix well and homogenize.
The suspension thus obtained consists of:
______________________________________Active compound 2%Vee Gum 5%CMC 0.1%Methyl parabene 0.2%Propyl parabene 0.5%Sorbitol (70% solution) 20%Flavoured water sufficient to 100%______________________________________
Flavoured water sufficient to 100% | This invention relates to anti-inflammatory pyridone derivatives, particularly 2,6-dimethyl-1,4-dihydro-4-oxo-3,5 pyridine-dicarboxylates and derivatives thereof which have an anti-inflammatory action, as well as compositions therewith, use of these compounds for their anti-inflammatory effect, and production thereof. These 4-oxo pyridines of the present invention, refer to in the literature as 4-(1H)-pyridones are suitably prepared by reacting a 2,6-dimethyl-4-oxo 3,5 pyrone-dicarboxylate with an aniline in an acidic medium such as acetic acid. | 2 |
TECHNICAL FIELD
[0001] The disclosure relates to the technical field of image pickup, and in particular to a shooting method and apparatus.
BACKGROUND
[0002] In order to meet life recording demands of people, there are more and more devices having recording functions, including cameras, mobile phones, video cameras, computers, laptops and the like, all of which are shooting apparatuses having shooting functions. Photographing and video-recording based on the shooting functions of the aforementioned devices have become the most convenient and most intuitive recording way.
[0003] In the conventional art, during shooting by a shooting apparatus, a screen of the shooting apparatus will display a shooting interface for a user to preview. Once the user exits the shooting interface, shooting is stopped or ended, and the shooting function cannot be used. A shooting method capable of closing camera preview is proposed in Chinese Patent application CN201310343019.1, in which the screen does not display the shooting interface during shooting and is in a black screen state instead. However, based on the above method, the shooting interface still occupies the screen during shooting, and merely in this case, the shooting interface is a black screen instead of a preview interface.
[0004] To sum up, during shooting by a conventional shooting apparatus, a camera module thereof only runs in the foreground, and occupies a current screen. Once exiting the current screen, the user cannot use the shooting function. Therefore, during shooting by the conventional shooting apparatus, other functions cannot be used at the same time, thus being not good for improving the operation efficiency. Each time when shooting is performed, it is necessary to start a camera module or switch the camera module to the foreground so as to be capable of performing shooting, so the image capturing speed is low.
SUMMARY
[0005] A main objective of the disclosure is to provide a shooting method and apparatus. The disclosure is intended to achieve using of other functions of a shooting apparatus at the same time of shooting, thus improving the operation efficiency.
[0006] To this end, the embodiments of the disclosure provide a shooting method, including:
[0007] a camera module is started, and a background shooting mode is entered;
[0008] in the background shooting mode, the camera module is controlled to run in the background; and
[0009] The camera module running in the background receives and executes a shooting instruction.
[0010] In an embodiment, the step that the background shooting mode is entered may include:
[0011] after the camera module is started, the background shooting mode is automatically entered; or
[0012] after the camera module exits a shooting interface, the background shooting mode is automatically entered; or
[0013] the camera module enters the background shooting mode according to an operation instruction.
[0014] In an embodiment, the step that the camera module running in the background receives and executes a shooting instruction may include:
[0015] Upon triggering of a preset key, a background control module releases a broadcast according to a key triggering event; and
[0016] the camera module running in the background receives the broadcast, acquires the key triggering event, takes the key triggering event as the shooting instruction, and executes the shooting instruction.
[0017] In an embodiment, the method may further include: when the camera module runs in the background, a processing module processes user's operations on other applications or programs.
[0018] The embodiments of the disclosure also provide a shooting apparatus, including a processing module, a camera module and a background control module, in which:
[0019] the processing module is configured to start the camera module;
[0020] the camera module is configured to enter a background shooting mode, and receive and execute a shooting instruction when running in the background; and
[0021] the background control module is configured to control the camera module to run in the background when the camera module enters the background shooting mode.
[0022] In an embodiment, the camera module may be configured to:
[0023] automatically enter the background shooting mode after being started; or,
[0024] automatically enter the background shooting mode after exiting a shooting interface; or,
[0025] enter the background shooting mode according to an operation instruction.
[0026] In an embodiment, the background control module may be configured to: release, upon triggering of a preset key, a broadcast according to a triggering event; and
[0027] the camera module may be configured to: receive the broadcast when running in the background, acquire the triggering event, take the triggering event as the shooting instruction and execute the shooting instruction.
[0028] In an embodiment, the processing module may be further configured to: process, when the camera module runs in the background, user's operations on other applications or programs.
[0029] In the shooting method according to the present disclosure, by adding a background shooting mode, a camera module runs in the background, and the camera module running in the background receives and executes a shooting instruction. Thus, a user may perform shooting while using other functions of a shooting apparatus, two activities do not conflict mutually, and the operation efficiency is improved. Moreover, when processing a great number of pictures shot in real time, the user may perform shooting and processing simultaneously, thereby improving the efficiency, and saving time and effort. Furthermore, since the camera module runs in the background, it is unnecessary to turn a screen on during shooting, and therefore quick image capturing may be implemented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a flowchart of a first embodiment for a shooting method according to the disclosure;
[0031] FIG. 2 is a flowchart of a second embodiment for a shooting method according to the disclosure; and
[0032] FIG. 3 shows a structural diagram of a shooting apparatus according to an embodiment of the disclosure.
[0033] Achievement of objectives, functional features and advantages of the disclosure will be further illustrated with reference to the drawings in conjunction with embodiments.
DETAILED DESCRIPTION
[0034] Referring to FIG. 1 , a first embodiment for a shooting method according to the disclosure is provided. The shooting method includes the steps as follows.
[0035] Step S 101 : A camera module is started.
[0036] As for a camera device, when the device is switched on, the camera module is automatically started. As for a terminal device having an image pickup function, when a camera application or program is opened, the camera module is started.
[0037] Step S 102 : An ordinary shooting mode is entered.
[0038] The ordinary shooting mode refers to: displaying a shooting interface (including a preview picture prior to shooting or in a shooting process) on a screen, and taking the shooting interface as a current interface of a shooting apparatus. In this case, the camera module runs in the foreground.
[0039] An android system is taken as an example. In the ordinary shooting mode, shooting and preview are implemented by means of an Activity assembly, herein the Activity is an application program assembly, provides a screen or an interactive interface, and interacts with a user to fulfil a certain task. All operations in the Activity are closely related to the user. The Activity is an assembly in charge of interacting with the user. A specified control may be displayed by means of setContentView(View). In an android application, an Activity is generally an independent screen, which may display some controls and may monitor and process events of the user to make a response. Activities communicate by means of Intent.
[0040] Step S 103 : It is determined whether to enter a background shooting mode.
[0041] Specifically, the background shooting mode may be entered according to an operation instruction of the user before shooting or in a shooting process. For example, a background shooting mode option is displayed on the shooting interface. When the user selects the option, the ordinary shooting mode is exited, and the background shooting mode is entered. Or, the background shooting mode is triggered by triggering a specific functional key or a preset touch or gesture action.
[0042] The background shooting mode may be automatically entered after the shooting apparatus exits the shooting interface. For example, before shooting or in the shooting process, the shooting interface is exited, a main interface or other application interfaces of the terminal device are entered, or a lock screen state, a standby state or a screen off state is presented, and in this case, the camera module automatically enters the background shooting mode.
[0043] Step S 104 : The camera module is controlled to run in the background.
[0044] After the background shooting mode is entered, a background control module controls a camera to run in the background.
[0045] Specifically, an android system is taken as an example. When the ordinary shooting mode is exited, the camera module in an Activity is closed, and a current interface is no longer displayed as a shooting interface. The background control module controls the camera module to run in background service, a setPreviewTexture( )interface built in the camera module is used, and one parameter SurfaceTexture needed therein may be randomly created. Since it is unnecessary to display a preview picture, the created category does not need to perform any processing. Thus, the shooting function of the camera module may be continuously used.
[0046] Step S 105 : The camera module receives and executes a shooting instruction.
[0047] The user may release the shooting instruction by triggering preset keys such as a camera key, an earphone key, a volume key, a Bluetooth key or other physical keys, and the shooting instruction may be released by a single or double click on one of the keys or a combination of the plurality of keys. The keys include built-in keys of the shooting apparatus or external keys. When the camera module runs in the background, a processing module processes user's operations on other applications or programs simultaneously.
[0048] Specifically, when the preset keys are triggered, although a response cannot be obtained from the background service, a response is made in a PhoneWindowManager of an original local framework layer where a triggering event occurs. Thus, when detecting that the preset keys are triggered, the background control module releases a broadcast according to the triggering event, such that a response event is made using a broadcast Intent and received by the camera module running in the background. A broadcast receiver is registered in the camera module in advance, and the broadcast may be received by means of the receiver, such that the triggering event is acquired, and taken as the shooting instruction to be executed, such as picture shooting, starting video shooting and ending video shooting.
[0049] Since the camera module runs in the background in the background shooting mode, the preview interface is not needed, and therefore the user may perform shooting while using other functions of the shooting apparatus. For example, when it is necessary to take a long time to continuously shoot a great number of pictures so as to combine the pictures and make gif and short videos, interval burst shooting is used. For example, interval time is set as 30 s (the interval time should be shorter if a finer effect is desired). In this case, if the ordinary shooting mode is used, pictures can be selected from a gallery and combined after shooting is completed, and the manufacturing efficiency is lower. However, if it is switched to the background shooting mode in the shooting process, since the camera module runs in the background, the user may get access to the gallery and select the shot pictures, simultaneous shooting and selecting may be implemented, the pictures are completely selected after shooting is completed, the pictures are directly combined, and gif or short videos are manufactured, thereby improving the manufacturing efficiency.
[0050] Furthermore, since the camera module runs in the background, the screen is not necessarily to be turned on. Thus, the advantage of quick shooting is provided. For example, after the camera module is started, the user turns the screen off and puts the shooting apparatus away. In this case, the camera module automatically enters the background shooting mode and runs in the background. When the user needs to capture a certain scenery or object, the user directly takes the shooting apparatus out and triggers the preset keys to perform shooting without the steps of turning the screen on, unlocking and starting the camera module, thereby greatly increasing the image capturing speed.
[0051] Since the camera module running in the background service is a Service, it is unnecessary to arrange a switch only in the camera module. The switch may be arranged at any places such as system setting.
[0052] Referring to FIG. 2 , a second embodiment for a shooting method according to the disclosure is provided. The shooting method includes the steps as follows.
[0053] Step S 201 : A camera module is started.
[0054] In this embodiment, a shooting apparatus may start the camera module under any situations. For example, the shooting apparatus is under a lock screen state, a standby state or a screen off state currently or a current screen displays a main interface or other application interfaces. The camera module may be started by means of a specific functional key or a preset operation instruction such as a gesture action.
[0055] Step S 202 : A background shooting mode is entered.
[0056] After the camera module is started, the background shooting mode is immediately and automatically entered.
[0057] Step S 203 : The camera module is controlled to run in the background.
[0058] Step S 204 : The camera module receives and executes a shooting instruction.
[0059] Thus, a user may start the camera module anytime and anywhere to shoot in the background, the shooting speed is increased, and there is no conflict against other functions which are being used on the shooting apparatus currently.
[0060] Referring to FIG. 3 , an embodiment for a shooting apparatus according to the disclosure is provided. The shooting apparatus includes a processing module, a camera module and a background control module.
[0061] The processing module is configured to start a camera module. Specifically, if the shooting apparatus is a camera device, when the device is opened, the processing module automatically starts the camera module. If the shooting apparatus is a terminal device having an image pickup function, when a camera application or program is opened, the processing module starts the camera module.
[0062] When the camera module runs in the background, the processing module processes user's operations on other applications or programs simultaneously.
[0063] The camera module is configured to select a shooting mode, and receives and executes a shooting instruction.
[0064] Wherein, the shooting mode includes an ordinary shooting mode and a background shooting mode. The ordinary shooting mode refers to: displaying a shooting interface (including a preview picture prior to shooting or in a shooting process) on a screen, and taking the shooting interface as a current interface of a shooting apparatus. In this case, the camera module runs in the foreground.
[0065] As for the background shooting mode, the camera module runs in the background. The camera module may enter the background shooting mode according to an operation instruction of the user before shooting or in a shooting process. The camera module may automatically enter the background shooting mode after the shooting apparatus exits the shooting interface.
[0066] Generally, after being started, the camera module automatically enters the ordinary shooting mode, and then is switched to the background shooting mode according to a preset rule. In some embodiments, after being started, the camera module automatically enters the background shooting mode, and then is switched to the ordinary shooting mode according to the operation instruction.
[0067] The background control module is configured to control, when the camera module enters the background shooting mode, the camera module to run in the background.
[0068] Receiving, when the camera module runs in the background, the shooing instruction is implemented by means of the ways as follows.
[0069] The user may release the shooting instruction by triggering preset keys such as a camera key, an earphone key, a volume key, a Bluetooth key or other physical keys, and the shooting instruction may be released by a single or double clicks on one of the keys or a combination of the plurality of keys. The keys include built-in keys of the shooting apparatus or external keys. When the preset keys are triggered, although a response cannot be obtained from the background service, a response is made in a PhoneWindowManager of an original local framework layer where a triggering event occurs. Thus, when detecting that the preset keys are triggered, the background control module releases a broadcast according to the triggering event, such that a response event is made using a broadcast Intent and received by the camera module running in the background. A broadcast receiver is registered in the camera module in advance, and the broadcast may be received by means of the receiver, such that the triggering event is acquired, and taken as the shooting instruction to be executed, such as picture shooting, starting video shooting and ending video shooting.
[0070] It is important to note that the technical features in the above method embodiment are correspondingly applicable in the apparatus, which will not be elaborated herein.
[0071] Accordingly, in the shooting apparatus of the disclosure, by adding a background shooting mode, a camera module runs in the background, and the camera module running in the background receives and executes a shooting instruction. Thus, a user may perform shooting while using other functions of a shooting apparatus, two activities do not conflict mutually, and the operation efficiency is improved. Moreover, when processing a great number of pictures shot in real time, the user may perform shooting and processing simultaneously, thereby improving the efficiency, and saving time and effort. Furthermore, since the camera module runs in the background, it is unnecessary to turn a screen on during shooting, and therefore quick image capturing may be implemented.
[0072] It is important to note that shooting by the shooting apparatus provided by the above embodiment is only illustrated with all the above divided functional modules. In practical application, the functions may be allocated to and implemented by different functional modules as needed. That is, the internal structure of the shooting apparatus is divided into different functional modules so as to complete all or some of the functions described above. In addition, the shooting apparatus provided by the above embodiment and the embodiment for the shooting method belong to the same concept, and a specific implementation process is detailed in the method embodiment, which will not be elaborated herein.
[0073] Those skilled in the art may understand that all or some of the steps in the above embodiment method may be implemented by controlling relevant hardware via programs, the programs may be stored in a computer readable storage medium, and the storage medium may be a Read-Only Memory/Random Access Memory (ROM/RAM), a magnetic disk or an optical disk.
[0074] It will be understood that the above is only the preferred embodiments of the disclosure and cannot limit the patent scope of the disclosure accordingly. Equivalent structure or equivalent flow transformations made using the description and drawings of the disclosure or direct or indirect applications to other relevant technical fields may fall within the patent protection scope of the disclosure in the same way.
[0075] Those skilled in the art may understand that all or some of the steps in the above embodiment method may be implemented by hardware relevant to program instructions, the programs may be stored in a computer readable storage medium, and when the programs are executed, the steps in the above method embodiment are also executed. The storage medium includes: various media capable of storing program codes such as a mobile storage device, an ROM, an RAM, a magnetic disk or an optical disk.
[0076] The above is only specific implementations of the disclosure. However, the protective scope of the disclosure is not limited thereto. Those skilled in the art may easily think of variations or replacements within the disclosed technical scope of the disclosure. These variations or replacements shall fall within the protective scope of the disclosure. Therefore, the protective scope of the disclosure shall refer to the protective scope of the claims. | An image capture method and apparatus, comprising the steps: activating a camera module and entering a background-running image capture mode; in the background running image capture mode, controlling the operation of the camera module in the background; and, when the camera module is running in the background, receiving an image capture command and executing same. | 7 |
RELATED APPLICATION
This application is a continuation-in-part of our copending application 09/943,998 filed Aug. 31, 2001, U.S. Pat. No. 6,495,063 having the same title.
TECHNICAL FIELD
This invention relates to inhibiting the freezing of water on coal and other particulate products, to maintain a substantially free-flowing state under otherwise subfreezing conditions. Under the influence of the invention, ice crystals which may be formed are weaker than would otherwise would be the case, also tending to maintain a substantially free-flowing state in coal piles and in other accumulations of particulate materials to be moved.
BACKGROUND OF THE INVENTION
Coal is stored, shipped and transferred in many locations having cold climates and in areas likely to experience temperatures below the freeze point of water. Most material handling equipment is designed to handle free-flowing materials, not materials which are frozen together in large chunks. Entire piles of coal have been known to accumulate significant amounts of water which may continue to accumulate over a period of days and become almost monolithic, frustrating efforts to break them apart and ship or transfer without extraordinary efforts.
The problem is stated succinctly by Parks et al in U.S. Pat. No. 4,117,214, column 1, lines 22-36: “For example, coal with as little as 4% moisture will, when frozen, cohere so strongly as to require special handling to break up the frozen mass. It thus becomes difficult to unload or dump railway cars, trucks and other conveyances used to transport coal, mineral ores and other finely divided solids. It also makes difficult the movement of coal out of outdoor coal storage piles in a condition for fuel or other use. Unloading frozen coal from railroad cars is time consuming, can result in blocked dump chutes and can often leave as much as 30 to 60 tons of coal in the car. Various techniques such as vibration, steam lances, fires under the cars, infrared heating in warming sheds and even dynamiting have been tried to unload frozen cars.” Parks et al go on to suggest applying to the coal a solution of a non-volatile organic compound and a water-soluble polyhydroxy compound or monoalkylether thereof, in order to weaken the ice that is nevertheless formed.
SUMMARY OF THE INVENTION
We have found that applying a solution of potassium formate on a pile or other mass of coal, minerals or other solid particulate material will inhibit the formation of coherent ice in the interstices of the particulate material. The effects of a solution of potassium formate are three: the freeze point of water is reduced, thus inhibiting the formation of ice; where ice is nevertheless formed in the presence of potassium formate, it is weaker than ice formed in the absence of potassium formate, and, if ice has already been formed prior to the application of potassium formate, the application of potassium formate will melt the ice.
Preferably the potassium formate solution is applied prior to the onset of snow or freezing rain. It may be applied in any effective manner, such as by pouring, but spraying is preferred. A spray may be conducted so that the coal or other particulates are wet with the solution at the time the snow or freezing rain arrives, or so that the water from the solution has evaporated by the time the precipitation arrives, leaving a residue of potassium formate on the particulates. In the former case, (prior to the arrival of precipitation), the still liquid solution of potassium formate on the surface of the particulates may be diluted with moisture from the snow in immediate contact with it before the pile is covered with snow, but the effect is that if ice forms, an underlayer of potassium formate solution is actually in contact with the coal or other particulate surface, and the freeze point of the solution is thereby reduced. Even when or if there are cycles of thawing and freezing, the concentration of potassium formate remains highest at the surface of the coal, mineral or other particulates, greatly decreasing the tendency of the weakened ice which does form to coalesce a large portion of the pile or other mass.
In the second case, where the potassium formate solution is sprayed on the previously formed ice or frozen mass of ice and snow, the solution will tend to dissolve the frozen mass, because of its lower freezing point.
In a third variation of the invention, finely divided solid potassium formate is sprinkled on the pile or mass of particulates prior to precipitation likely to form a frozen mass in the interstices of the particulates.
The term “particulates” is used herein to refer to both small and large substantially water-insoluble particles, ranging from finely ground material to large lumps such as large lumps of coal, and includes materials and ores having a wide range of hardness and moisture contents.
DETAILED DESCRIPTION OF THE INVENTION
Table 1 shows the freeze points of increasing concentrations of potassium formate in water.
TABLE 1
Potassium Formate Solution Freeze Points
Percent by Weight KCOOH
Freeze Point, ° F.
4
28
8
23
12
18
16
11
20
4
24
−5
28
−13
32
−25
36
−37
40
−49
44
−61
48
−75
When applying the potassium formate solution by spraying ahead of precipitation likely to freeze, we may use concentrations of 1% to 76% by weight, preferably 15% to 60%, and more preferably 30% to 55%. When applying the potassium formate solution to an already frozen mass of material, a concentration of 60% to 76% is preferred; most preferably it is applied in the form of a high pressure spray. By a high pressure spray, we mean one having a pressure higher than normally obtained from a municipal water pressures; it may be in the form of a solid stream or as one or more jets. The solution may be heated.
Experiments were performed to determine the effectiveness of the invention on the cohesive strength of wet coal below 0° C. Comparisons were made of 50% ethylene glycol in water (Control) to potassium formate at 38 and 50 weight percent in water. Minus 6 mesh coal was first thoroughly mixed and divided into three samples which were adjusted to 5%, 10%, and 15% moisture content. Each sample was then divided into five portions and placed in separate plastic bags. Using a syringe, the three solutions were added to each bag at a rate equivalent to two pints per ton, and thoroughly mixed to wet the surfaces of the particulates. For each of the three solutions to be tested, five substantially similar 1 kg wet samples were poured onto pans previously lubricated with mold release agent. The 1 kg samples of coal were consolidated by dropping them a distance of 1 inch to a laboratory bench, and then frozen on the pans at −10° C. for 24 hours.
The pans were then inverted and the frozen samples dropped onto a steel grate having 1.25 inch square openings. The procedure for each drop was to drop from the prescribed height, remove and weigh the coal which passed through the grate, retrieve the remaining coal from the top of the grate, and drop it from the next incremental height. The coal passed was weighed, the remaining coal retrieved and dropped from the next incremental height. The procedure was iterated until all the coal passed or until the drop height limit of 8 feet was reached. At certain heights, as many as 5 drops were used and the results averaged; at other heights, fewer drops were needed, as it was clear, for example, that virtually all the coal would pass. Following, in Table 2, is a summary of the results.
TABLE 2
Weight Percent Coal Passing Grate
5% Moisture
10% Moisture
15% Moisture
Drop Ht, ft
50/50 EG
38% KF
50% KF
50/50 EG
38% KF
50% KF
50/50 EG
38% KF
50% KF
2
100
100
100
43
42
37
4
5
5
3
100
100
100
83
78
79
13
11
10
4
100
100
100
99
99
98
22
21
19
5
100
100
100
100
100
100
33
31
32
6
100
100
100
100
100
100
48
44
47
7
100
100
100
100
100
100
63
56
58
8
100
100
100
100
100
100
77
70
72
KF = potassium formate
EG = ethylene glycol
The results demonstrate that potassium formate solution is substantially equivalent to glycol in effectiveness.
The environmental acceptability of potassium formate, however, is superior to glycol.
Corrosion inhibitors commonly used with alkali metal or alkaline earth metal ice melters may be used with our potassium formate solutions; likewise, small amounts of water soluble polymers (an example is polyacrylamide) may be used in our invention together with the potassium formate to reduce loss through drainage. That is, the polymer will impart a viscosity to the solution sufficient to cause an increased portion of the solution to adhere to the particulates and remain on them to be effective in reducing the freezing point of any water that comes in contact with it.
Thus, our invention includes a method of inhibiting the solidification by freezing of a mass of solid particulates subject to precipitation comprising spraying onto said mass prior to said precipitation an aqueous solution comprising potassium formate. It will be understood that, either by accident or design, the solution may dry before the precipitation arrives, leaving a precipitate of potassium formate on the particulates, which will be dissolved by snow or freezing rain, thus reforming a potassium formate solution on the surfaces of the particulates.
Our invention also includes a method of reducing the cohesiveness of a mass of particulates held together by frozen precipitation comprising applying thereto an effective amount of a solution comprising potassium formate. The application may be accomplished by spraying under high or low pressure.
In any case, whether the potassium formate solution is applied before or after ice formation, it may include effective amounts of more or less conventional corrosion inhibitors, or any other corrosion inhibitor effective to reduce corrosion, particularly where oxygen may be dissolved in the solution, as may be expected. Where the coal or other particulate pile is in a steel container such as a railroad car or a steel bin, corrosion inhibitors known to be useful for steel are preferred. Corrosion inhibitors may be used such as triethanolamine, alkali metal and, less preferably, alkaline earth metal, metaphosphates, pyrophosphates, phosphonates and orthophosphates, molybdates, nitrates, nitrites and borates, organic amines and organic acids such as azeleic, sebacic, ascorbic, malonic, oxalic, maleic, known to inhibit corrosion in aqueous systems, that is, acids of the formula RCOOH or HCOOCRCOOH where R is a hydrocarbyl group of 0 to 10 carbon atoms and their alkali metal, alkaline earth metal and ammonium salts. Small amounts (from 0.01% by weight to 5% by weight, preferably 0.1-3%)) may be effective to a degree correlative to the amount. Accordingly, effective corrosion inhibitors may comprise silicates, phosphates, high molecular weight copolymers or phosphonates, or mixtures of two or more of these classes of compounds. Other examples of corrosion inhibitors include sodium metasilicate, tripotassium phosphate, styrene-maleic acid copolymers and aminotris(methylenephosphonic acid)/zincsulfate. Mixtures of any of the corrosion inhibitors mentioned herein may be quite effective. Possible mixtures include small amounts of sodium metasilicate, tripotassium phosphate, styrene-maleic acid copolymers and, for example, a mixture of 1 part by weight of aminotris(methylenephosphonic acid) and 5 parts by weight of zinc sulfate. Aspartic acid, glycine, polyglycine, glutamic acid, polyglutamic acid, alone or together with aminophosphonic acids and their salts, may also be used, as can polyaspartic acid and phosphonocarboxylic acid oligomers and their salts, as disclosed in U.S. Pat. No. 6,207,079, and sodium lactate as described in U.S. Pat. No. 6,149,833. Cinnamic acid, alkylcinnamic acid, and alkoxycinnamic acid and their salts, as disclosed in U.S. Pat. No. 5,961,875, zinc amino carboxylates such as disclosed in U.S. Pat. No. 6,127,467, and any corrosion inhibitor known to be effective in cooling water systems, such as discussed in U.S. Pat. No. 6,077,460, only one of numerous patents on the subject which are also of interest in reciting corrosion inhibitors for aqueous systems also useful in our invention. Any corrosion inhibitor effective for protecting steel in an aqueous environment may be used.
A “package” of some of the corrosion inhibitors mentioned above has been demonstrated to be effective in inhibiting corrosion of potassium formate solution under laboratory conditions. While an aerated solution of 37% potassium formate yielded weight losses on 15 g carbon steel coupons of 36.6 mg after two weeks at ambient temperature, an aerated 27% potassium formate solution yielded only a 1 9.3 mg loss after 26 days, in the presence of a corrosion inhibitor package of the following composition, by weight in the solution:
Magnesium formate
0.2%
Polyacrylic Acid (about 2500 mw)
1.0%
Sodium metabisulfite
0.5%
Sodium Molybdate
0.2%
Potassium azelate
0.4%
Tolyltriazole
0.0245%
In addition, our invention includes the use of a viscosifier in the potassium formate solution. The viscosifier is used to inhibit the draining of the potassium formate solution away from contact with the coal or other particulates. That is, the ability of the potassium forrnate solution to inhibit the formation of ice in the interstices and otherwise on the surface of the coal is enhanced by the presence of the viscosifier, which reduces the incidence of waste by causing the solution to remain on the coal surface and in the interstices of the pile rather than draining to the floor of the container. The viscosifier is effective not only on the open or top surface of the coal or other particulates, but is especially effective where it is between two particulate surfaces—that is, the viscosifier is especially effective because of its ability to enable the solution to fill substantial portions of the voids between particulates, remaining substantially stationary therein, thereby inhibiting draining and waste of the solution which otherwise might ineffectively drain through the pile. In a coal pile, it is desirable that a substantial portion of the void space between adjacent coal pieces near the surface of the pile—that is, coal pieces contacting each other within about 0.5 meter from the surface—be filled with viscosified potassium formate solution Desirably, the void space within about one centimeter in all directions from a contact point of two adjacent pieces of coal should be filled with viscosified solution; as a practical matter, at least about 25% of the contact points in the uppermost 0.5 meter should be so filled. Viscosifiers are generally water soluble polymers, which may be either synthetic or natural, i.e. biopolymers. Suitable synthetic polymers include polyacrylamide, copolymers of acrylamide and acrylic acid, N,N-dimethylacrylamide, 2-acrylamido-2-propane sulfonic acid (AMPS), and quaternary monomers such as 2-(methacryloxy)ethyl trimethyl ammonium sulfate, diallyl dimethyl ammonium chloride (DADMAC), homopolymers of any of the monomers just named, polyvinylalcohol, polyethyleneoxide, polyvinylpyrrolidinone, and any of numerous other viscosifying synthetic polymers known in the art, including some which may be slightly crosslinked with difunctional monomers such as methylene bis acrylamide. Natural polymers that are suitable include various polygalactomannans, guar, xanthan, locust bean gum, starch, cellulose, and derivatives of any of these such as carboxymethyl guar, carboxymethylhydroxyethylguar, carboxymethylcellulose, carboxymethyl hydroxyethyl cellulose, and any other natural or biopolymer or a derivative thereof that will viscosify an aqueous solution. Such materials may be used in any amount effective to inhibit draining in the pile to any degree—that is, for example, if the solution is effective to reduce draining by one percent of the amount of solution that would otherwise drain through the pile on spraying, to reach the bottom of the pile, leaving the remaining portion of the solution to wet the coal or other particulate material and reside in the interstices, we consider the viscosifier to be effective. Generally, effective amounts will range from 0.001% by weight to 5% by weight, preferably 0.01-3%, more preferably 0.1-2%, depending on the particular viscosifier and the type of particulate.
The potassium formate solution may be used with a corrosion inhibitor, a viscosifier, or both. A preferred potassium formate solution including both is one comprising 0.05% aminotrisphosphonic acid or a salt thereof and 0.1% guar. However, any of the above recited corrosion inhibitors may be used together with any of the above recited viscosifiers in the amounts mentioned above. | Coal and other piles of particulates exposed to the weather are inhibited from freezing by treating them with potassium formate. A viscosifier is used to retain the solution in the interstices and voids between the particulates, inhibiting drainage and waste of the solution. Corrosion inhibitors are also compatible with the solution. | 1 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application 61/086,799 (Attorney Docket No. 027364-003200US), filed on Aug. 7, 2008, commonly assigned, and of which is incorporated by reference in its entirety for all purposes hereby.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] NOT APPLICABLE
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
[0003] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0004] The present invention generally relates to processing of materials for growth of crystals. More particularly, the present invention provides a method for obtaining a gallium-containing nitride crystal by an ammonobasic or ammonoacidic technique, but there can be others. In other embodiments, the present invention provides an apparatus for large scale processing of nitride crystals, but it would be recognized that other crystals and materials can also be processed. Such crystals and materials include, but are not limited to, GaN, AlN, InN, InGaN, AlGaN, and AlInGaN, and others for manufacture of bulk or patterned substrates. Such bulk or patterned substrates can be used for a variety of applications including optoelectronic devices, lasers, light emitting diodes, solar cells, photoelectrochemical water splitting and hydrogen, photodetectors, integrated circuits, and transistors, among other devices.
[0005] Gallium nitride containing crystalline materials serve as a starting point for manufacture of conventional optoelectronic devices, such as blue light emitting diodes and lasers. Such optoelectronic devices have been commonly manufactured on sapphire or silicon carbide substrates that differ from the deposited nitride layers. In the conventional Metallo-Organic Chemical Vapor Deposition (MOCVD) method, deposition of GaN is performed from ammonia and organometallic compounds in the gas phase. Although successful, conventional growth rates achieved make it difficult to provide a bulk layer of GaN material. Additionally, dislocation densities are also high and lead to poorer optoelectronic device performance.
[0006] Other techniques have been proposed for obtaining bulk monocrystalline gallium nitride. Such techniques include use of epitaxial deposition employing halides and hydrides in a vapor phase and is called Hydride Vapor Phase Epitaxy (HVPE) [“Growth and characterization of freestanding GaN substrates,” K. Motoki et al., Journal of Crystal Growth 237-239, 912 (2002)]. Unfortunately, drawbacks exist with HVPE techniques. In some cases, the quality of the bulk monocrystalline gallium nitride is not generally sufficient for high quality laser diodes because of issues with dislocation density, stress, and the like.
[0007] Techniques using supercritical ammonia have been proposed. Peters has described the ammonothermal synthesis of aluminium nitride [J. Cryst. Growth 104, 411 418 (1990)]. R. Dwiliński, et al. have shown, in particular, that it is possible to obtain a fine-crystalline gallium nitride by a synthesis from gallium and ammonia, provided that the latter contains alkali metal amides (KNH 2 or LiNH 2 ). These and other techniques have been described in “AMMONO method of BN, AlN, and GaN synthesis and crystal growth”, Proc. EGW-3, Warsaw, Jun. 22 24, 1998, MRS Internet Journal of Nitride Semiconductor Research, Http://nsr.mij.mrs.org/3/25, “Crystal growth of gallium nitride in supercritical ammonia” J. W. Kolis, et al., J. Cryst. Growth 222, 431 434 (2001), and Mat. Res. Soc. Symp. Proc. Vol. 495, 367 372 (1998) by J. W. Kolis, et al. However, using these supercritical ammonia processes, no wide scale production of bulk monocrystalline was achieved.
[0008] Dwiliński, in U.S. Pat. Nos. 6,656,615, 7,160,388, and 7,335,262, and D'Evelyn, in U.S. Pat. Nos. 7,078,731 and 7,101,433, which are hereby incorporated by reference in their entirety, generally describe apparatus and methods for ammonothermal crystal growth of GaN. These conventional methods are useful for growth of relatively small GaN crystals but have limitations for large scale manufacturing. For example, apparatus with an inner diameter of 40 mm is somewhat useful for growing 1 ″ diameter GaN crystals but is generally not suitable for large scale growth of crystals. Other autoclave related techniques are described in U.S. Pat. Nos. 3,245,760, 2,607,108, and 4,030,966. Although somewhat successful, drawbacks exist with these conventional ammonothermal techniques.
[0009] From the above, it is seen that improved techniques for crystal growth are highly desired.
BRIEF SUMMARY OF THE INVENTION
[0010] According to the present invention, techniques related to processing of materials for the growth of crystal are provided. More particularly, the present invention provides a method for obtaining a gallium-containing nitride crystal by an ammonobasic or ammonoacidic technique, but there can be others. In other embodiments, the present invention provides an apparatus for large scale processing of nitride crystals, but it would be recognized that other crystals and materials can also be processed. Such crystals and materials include, but are not limited to, GaN, AlN, InN, InGaN, AlGaN, and AlInGaN, and others for manufacture of bulk or patterned substrates. Such bulk or patterned substrates can be used for a variety of applications including optoelectronic devices, lasers, light emitting diodes, solar cells, photoelectrochemical water splitting and hydrogen generation, photodetectors, integrated circuits, and transistors, among other devices.
[0011] In a specific embodiment, the present invention provides an apparatus and method for large-scale manufacturing of gallium nitride. In a specific embodiment, the present apparatus comprises a large diameter autoclave and a raw material basket. Methods include metered addition of one or more dopants in the raw material and control of atmosphere during crystal growth. The apparatus and methods are scalable up to very large volumes and are cost effective.
[0012] In a specific embodiment, the present invention provides a process for growing a crystalline gallium-containing nitride, e.g., GaN. The process includes providing a high pressure apparatus comprising gallium-containing feedstock in one zone, at least one seed in another zone, an azide mineralizer, and at least one metal. In a specific embodiment, the azide mineralizer and the metal are provided in a predetermined ratio such that nitrogen generated by decomposition of the azide mineralizer and hydrogen generated by reaction of the metal with a supercritical fluid are in a ratio of approximately 1:3. In a specific embodiment, the method includes processing one or more portions of the gallium-containing feedstock in the supercritical fluid to provide a supercritical solution comprising at least gallium containing species at a first temperature. Preferably, the method grows crystalline gallium-containing nitride material from the supercritical solution on the seed at a second temperature, which is characterized to cause the gallium containing species to form the crystalline gallium containing nitride material on the seed.
[0013] Still further, the present invention provides a process for growing a crystalline gallium-containing nitride, e.g., GaN. The process includes providing a high pressure apparatus comprising gallium-containing feedstock in one zone, at least one seed in another zone, an azide mineralizer, at least one metal, and a catalyst within a vicinity of either or both the one zone or/and the other zone. In a specific embodiment, the azide mineralizer and the metal are provided in a predetermined ratio such that nitrogen generated by decomposition of the azide mineralizer and a hydrogen gas species generated by reaction of at least the metal with a supercritical ammonia are in a ratio of approximately 1:3 and greater. The method includes processing one or more portions of the gallium-containing feedstock in the supercritical ammonia to provide a supercritical ammonia solution comprising at least gallium containing species at a first temperature. The method grows crystalline gallium-containing nitride material from the supercritical ammonia solution on the seed at a second temperature, which is characterized to cause the gallium containing species to form the crystalline gallium containing nitride material on the seed. In a specific embodiment, the method generates the hydrogen gas species from at least the reaction between the metal and the supercritical ammonia fluid. The method also includes processing the hydrogen gas species using at least the catalyst to convert the hydrogen gas species and a nitrogen gas species to the supercritical ammonia fluid.
[0014] In a specific embodiment, the present invention provides a system for growing a crystalline gallium-containing nitride. The system has a high pressure apparatus comprising gallium-containing feedstock in one zone, at least one seed in another zone, an azide mineralizer, and at least one metal. The azide mineralizer and the metal are provided in a predetermined ratio such that nitrogen generated by decomposition of the azide mineralizer and hydrogen generated by reaction of the metal with a supercritical fluid are in a ratio of a predetermined amount, e.g., approximately 1:3.
[0015] Benefits are achieved over pre-existing techniques using the present invention. In particular, the present invention enables a cost-effective high pressure apparatus for growth of crystals such as GaN, AlN, InN, InGaN, and AlInGaN and others. In a specific embodiment, the present method and apparatus can operate with components that are relatively simple and cost effective to manufacture. Depending upon the embodiment, the present apparatus and method can be manufactured using conventional materials and/or methods according to one of ordinary sill in the art. The present apparatus and method enable cost-effective crystal growth and materials processing under extreme pressure and temperature conditions in batch volumes larger than 0.3 liters, larger than 1 liter, larger than 3 liters, larger than 10 liters, larger than 30 liters, larger than 100 liters, and larger than 300 liters according to a specific embodiment. Depending upon the embodiment, one or more of these benefits may be achieved. These and other benefits may be described throughout the present specification and more particularly below.
[0016] The present invention achieves the benefits and others in the context of known process technology. However, a further understanding of the nature and advantages of the present invention may be realized by reference to the latter portions of the specification and attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a simplified diagram of an autoclave apparatus according to an embodiment of the present invention.
[0018] FIGS. 1A and 1B are simplified diagrams illustrating a basket apparatus for use in material processing for crystal growth according to an embodiment of the present invention.
[0019] FIG. 2 is a simplified diagram illustrating solubility of GaN plotted against pressure according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] According to the present invention, techniques related to processing of materials for growth of crystal are provided. More particularly, the present invention provides a method for obtaining a gallium-containing nitride crystal by an ammonobasic or ammonoacidic technique, but there can be others. In other embodiments, the present invention provides an apparatus for large scale processing of nitride crystals, but it would be recognized that other crystals and materials can also be processed. Such crystals and materials include, but are not limited to, GaN, AlN, InN, InGaN, AlGaN, and AlInGaN, and others for manufacture of bulk or patterned substrates. Such bulk or patterned substrates can be used for a variety of applications including optoelectronic devices, lasers, light emitting diodes, solar cells, photoelectrochemical water splitting and hydrogen generation, photodetectors, integrated circuits, and transistors, among other devices.
[0021] In the present invention the following definitions apply according to one or more embodiments. Such definitions are not intended to be limiting, but should be helpful to the reader.
[0022] Gallium-containing nitride means a nitride of gallium and optionally other element(s) of group XIII (according to IUPAC, 1989). It includes, but is not restricted to, the binary compound GaN, ternary compounds such as AlGaN, InGaN and also AlInGaN, where the ratio of the other elements of group XIII to Ga can vary in a wide range.
[0023] Bulk monocrystalline gallium-containing nitride means a monocrystalline substrate made of gallium-containing nitride from which optoelectronic devices such as LED or LD can be formed by epitaxial methods as MOCVD and HVPE.
[0024] Supercritical solvent means a fluid in a supercritical state. It can also contain other components in addition to the solvent itself as long as these components do not substantially influence of disturb function of supercritical solvent. In particular, the solvent can contain ions of alkali metals. A superheated solvent, that I, a solvent heated to a temperature above its boiling point at atmospheric pressure, may also be referred to as supercritical. The latter designation may be useful in cases where the precise critical point of the solvent is not known, due, for example, to the presence of dissolved alkali ions and group III ions, molecules, or complexes.
[0025] Supercritical solution is used when referring to the supercritical solvent when it contains gallium in a soluble form originating from the etching of gallium-containing feedstock.
[0026] Etching of gallium-containing feedstock means a process (either reversible of irreversible) in which said feedstock undergoes a chemical reaction and is taken up to the supercritical solvent as gallium in a soluble form, possibly gallium-complex compounds.
[0027] Crystallization means the reverse process of etching, in what gallium in a soluble form, for example, gallium-complex compounds, undergoes a chemical reaction to form crystalline gallium-containing nitride, preferably as an epitaxial layer on a seed crystal.
[0028] Solubility means the concentration of dissolved gallium in a soluble form, for example, gallium-complex compounds, that is in chemical equilibrium with crystalline gallium-containing nitride at a given temperature, pressure, and mineralizer concentration.
[0029] Processing the feedstock means a process whereby gallium in a soluble form is prepared from the feedstock. In the case where the feedstock comprises gallium-containing nitride, processing means etching. In the case where the feedstock comprises a soluble gallium-containing compound, processing means dissolution.
[0030] Gallium-complex compounds are complex compounds, in which a gallium atom is a coordination center surrounded by ligands, such as NH 3 molecules or its derivatives, like NH 2 − , NH 2− , etc.
[0031] Negative temperature coefficient of solubility means that the solubility of the respective compound is a monotonically decreasing function of temperature if all other parameters are kept constant. Similarly, positive pressure coefficient of solubility means that, if all other parameters are kept constant, the solubility is a monotonically increasing function of pressure.
[0032] Over-saturation of supercritical solution with respect to gallium-containing nitride means that the concentration of gallium in a soluble form in said solution is higher than that in chemical equilibrium. In the case of etching of gallium-containing nitride in closed system, such an over-saturation can be achieved by either increasing the temperature and/or decreasing the pressure.
[0033] Spontaneous crystallization means an undesired process where nucleation and growth of the gallium-containing nitride from over-saturated supercritical solution take place at any site within an autoclave except at the surface of a seed crystal where the growth is desired. Spontaneous crystallization also comprises nucleation and disoriented growth on the surface of seed crystal.
[0034] Selective crystallization on a seed means a process of crystallization on a seed carried out without spontaneous crystallization.
[0035] Autoclave means a closed container which has a reaction chamber where the ammonobasic process according to the present invention is carried out. As conventionally used in the art, closed is understood to mean sealed and gas tight in the ordinary meaning. As conventionally used in the art, an autoclave is understood to be externally heated, that is, so that the temperature of the inner walls of the autoclave is approximately equal to the temperature of the supercritical fluid proximate to the autoclave walls in the ordinary meaning.
[0036] High pressure apparatus means an apparatus capable of containing supercritical ammonia and a growth environment for gallium-containing nitride at temperatures between about 100 degrees Celsius and about 800 degrees Celsius and pressures between about 1 kilobar (kbar) and about 10 kbar. In one embodiment, the high pressure apparatus comprises an autoclave, as described by U.S. Pat. No. 7,335,262, which is hereby incorporated by reference in its entirety. In another embodiment, the high pressure apparatus is an internally heated high pressure apparatus, as described in U.S. Pat. No. 7,125,453, and in U.S. Patent Applications 2006/0177362A1 and U.S. Ser. No. 12/133,364, which are hereby incorporated by reference in their entirety.
[0037] In the discussion that follows, the apparatus is described as being vertically oriented. In another embodiment, the apparatus is instead horizontally oriented or oriented at an oblique angle intermediate between vertical and horizontal, and may be rocked so as to facilitate convection of the supercritical fluid within the high pressure apparatus.
[0038] The present invention can provide a gallium-containing nitride monocrystal having a large size and a high quality. Such gallium-containing nitride crystals can have a surface area of more than 2 cm 2 and a dislocation density of less than 10 6 cm −2 . Gallium-containing nitride crystals having a thickness of at least 200 μm (preferably at least 500 μm) and a FWHM of 50 arcsec or less can also be obtained. Depending on the crystallization conditions, it is possible to obtain gallium-containing nitride crystals having a volume of more than 0.05 cm 3 , preferably more than 0.1 cm 3 using the processes of the invention.
[0039] As was explained above, the gallium-containing nitride crystal is a crystal of nitride of gallium and optionally other element(s) of Group XIII (the numbering of the Groups is given according to the IUPAC convention of 1989 throughout this application). These compounds can be represented by the formula Al x Ga 1-x-y In y N, wherein 0≦x<1, 0≦y<1, 0≦x+y<1; preferably 0≦x<0.5 and 0≦y<0.5. Although in a preferred embodiment, the gallium-containing nitride is gallium nitride, in a further preferred embodiment part (e.g. up to 50 mol.-%) of the gallium atoms can be replaced by one or more other elements of Group XIII (especially Al and/or In).
[0040] The gallium-containing nitride may additionally include at least one donor and/or at leas one acceptor and/or at least one magnetic dopant to alter the optical, electrical and magnetic properties of the substrate. Donor dopants, acceptor dopants and magnetic dopants are well-known in the art and can be selected according to the desired properties of the substrate. Preferably the donor dopants are selected from the group consisting of Si and O. As acceptor donors Mg and Zn are preferred. Any known magnetic dopant can be included into the substrates of the present invention. A preferred magnetic dopant is Mn and possibly also Ni and Cr. The concentrations of the dopants are well-known in the art and depend on the desired end application of the nitride. Typically the concentrations of these dopants are ranging from 10 17 to 10 21 cm −3 .
[0041] Due to the production process the gallium-containing nitride crystal can also contain alkali elements, usually in an amount of more than about 0.1 ppm. Generally it is desired to keep the alkali elements content lower than 10 ppm, although it is difficult to specify what concentration of alkali metals in gallium-containing nitride has a disadvantageous influence on its properties.
[0042] It is also possible that halogens are present in the gallium-containing nitride. The halogens can be introduced either intentionally (as a component of the mineralizer) or unintentionally (from impurities of the mineralizer of the feedstock). It is usually desired to keep the halogen content of the gallium-containing nitride crystal in the range of about 0.1 ppm or less.
[0043] In a specific embodiment, the process of the invention is a supercritical crystallization process, which includes at least two steps: an etching step at a first temperature and at a first pressure and a crystallization step at a second temperature and at a second pressure. Since generally high pressures and/or high temperatures are involved, the process according to the invention is preferably conducted in an autoclave. The two steps (i.e. the etching step and the crystallization step) can either be conducted separately or can be conducted at least partially simultaneously in the same reactor.
[0044] For conducting the two steps separately the process can be conducted in one reactor but the etching step is conducted before the crystallization step. In this embodiment the reactor can have the conventional construction of one single chamber. The process of the invention in the two-step embodiment can be conducted using constant pressure and two different temperatures or using constant temperature and two different pressures. It is also possible to use two different pressures and two different temperatures. The exact values of pressure and temperature should be selected depending on the feedstock, the specific nitride to be crystallized and the solvent. Generally the pressure is in the range of 1 to 10 kbar, preferably 1 to 5.5 and more preferably 1.5 to 3 kbar. The temperature is in the range of 100 degrees Celsius to 800 degrees Celsius, preferably 300 degrees Celsius to 600 degrees Celsius, more preferably 400 degrees Celsius to 550 degrees Celsius. If two different pressures are employed, the difference in pressure should be from 0.1 kbar to 9 kbar, preferably from 0.2 kbar to 3 kbar. However, if the etching and crystallization are controlled by the temperature, the difference in temperature should be at least 1 degree Celsius, and preferably from 5 degrees Celsius to 150 degrees Celsius.
[0045] In a preferred embodiment, the etching step and the crystallization step are conducted at least partially simultaneously in the same container. For such an embodiment the pressure is practically uniform within the container, while the temperature difference between the etching zone and crystallization zone should be at least 1 degree Celsius, and preferably is from 5 degrees Celsius to 150 degrees Celsius. Furthermore, the temperature difference between the etching zone and the crystallization zone should be controlled so as to ensure chemical transport in the supercritical solution, which takes place through convection.
[0046] A possible construction of a preferred container is given in FIG. 1 . For conciseness and ease of understanding in the following, the process will be explained particularly with respect to this preferred embodiment. However, the invention can be conducted with different container constructions as long as the principles outlined in the specification and the claims are adhered to.
[0047] In a preferred embodiment of the invention, the process can be conducted in an apparatus comprising an autoclave 1 having an internal space and comprising at least one device 4 , 5 , 6 for heating the autoclave to at least two zones having different temperatures, wherein the autoclave comprises a device which separates the internal space into an etching zone 13 and a crystallization zone 14 . These two zones having different temperatures should preferably coincide with the etching zone 13 and the crystallization zone 14 . The device which separates the internal space of the autoclave can be, for example, at least one baffle 12 having at least one opening 2 . Examples are baffles having a central opening, circumferential openings or a combination thereof. The size of the opening(s) 2 should be large enough to allow transport between the zones but should be sufficiently small to maintain a temperature gradient in the reactor. The appropriate size of the opening depends on the size and the construction of the reactor and can be easily determined by a person skilled in the art.
[0048] In a specific embodiment, two different heating devices can be employed, the position of which corresponds to etching zone 13 and the crystallization zone 14 . However, it has been observed that transport of gallium in a soluble form from the etching zone 13 to the crystallization zone 14 can be further improved if a third cooling means 6 is present between the first and the second heating devices and is located at approximately the position of the separating device. The cooling means 6 can be realized by liquid (e.g. water) cooling or preferably by fan cooling. The heating devices are powered electrically, by either inductive or, preferably, resistive heating means. Use of a heating 4 -cooling 6 -heating 5 configuration gives wider possibilities in forming the desired temperature distribution within the autoclave. For example, it enables to obtain low temperature gradients in most of the crystallization zone 14 and of the etching zone 13 , and a high temperature gradient in the region of baffle 12 . In a specific embodiment, the apparatus includes one or more basket devices 19 that are described in more detail below.
[0049] In a specific embodiment, the autoclave may further comprise a liner or capsule (not shown in FIG. 1 ). The liner or capsule may comprise a precious metal, such as at least one of silver, gold, platinum, palladium, rhodium, iridium, or ruthenium. The liner may prevent or inhibit corrosion of the walls of the autoclave and/or contamination of the growing crystals by the components of the autoclave. Examples of suitable liners or capsules are described in Japanese patent application number JP2005289797A2, U.S. Pat. No. 7,125,453, U.S. patent application Ser. No. 12/133,365, and K. Byrappa and M. Yoshimura on pages 94-96 and 152 of Handbook of Hydrothermal Technology (Noyes Publications, Park Ridge, N.J., 2001), each of which is hereby incorporated by reference in their entirety.
[0050] When the process of the present invention is conducted, providing a gallium-containing feedstock, an alkali metal-containing component, at least one crystallization seed and a nitrogen-containing solvent are provided in at least one container. In the preferred apparatus described above, the gallium-containing feedstock is placed in the etching zone and the at least one crystallization seed is placed in the crystallization zone. The alkali metal containing component is also preferably placed in the etching zone. Then the nitrogen-containing solvent is added into the container, which is then closed. Subsequently the nitrogen-containing solvent is brought into a supercritical state, e.g. by pressure and/or heat.
[0051] In the present invention any materials containing gallium, which can be etched or dissolved in the supercritical solvent under the conditions of the present invention, can be used as a gallium-containing feedstock. Typically the gallium-containing feedstock will be a substance or mixture of substances, which contains at least gallium, and optionally alkali metals, other Group XIII elements, nitrogen, and/or hydrogen, such as metallic Ga, alloys and inter-metallic compounds, hydrides, amides, imides, amidoimides, azides. Suitable gallium-containing feedstocks can be selected from the group consisting of gallium nitride GaN, azides such as Ga(N 3 ) 3 , imides such as Ga 2 (NH) 3 , amido-imides such as Ga(NH)NH 2 , amides such as Ga(NH 2 ) 3 , hydrides such as GaH 3 , gallium-containing alloys, metallic gallium and mixtures thereof. Preferred feedstocks are metallic gallium and gallium nitride and mixtures thereof. Most preferably, the feedstock is metallic gallium or gallium nitride. If other elements of Group XIII are to be incorporated into the gallium-containing nitride crystal, corresponding compounds or mixed compounds including Ga and the other Group XIII element can be used. If the substrate is to contain dopants or other additives, precursors thereof can be added to the feedstock.
[0052] The form of the feedstock is not particularly limited and it can be in the form of one or more pieces or in the form of a powder. If the feedstock is in the form of a powder, care should be taken that individual powder particles are not transported from the etching zone to the crystallization zone, where they can cause irregular crystallization. It is preferable that the feedstock is in one or more pieces and that the surface area of the feedstock is larger than that of the crystallization seed.
[0053] The nitrogen-containing solvent employed in the present invention should be able to form a supercritical fluid, in which gallium can be etched in the presence of alkali metal ions. Preferably the solvent is ammonia, a derivative thereof or mixtures thereof. An example of a suitable ammonia derivative is hydrazine. Most preferably the solvent is ammonia. To reduce corrosion of the reactor and to avoid side-reactions, halogens e.g. in the form of halides are preferably not intentionally added into the reactor unless a liner or capsule is present. Although traces of halogens may be introduced into the system in the form of unavoidable impurities of the starting materials, care should be taken to keep the amount of halogen as low as possible. Due to the use of a nitrogen-containing solvent such as ammonia it is not necessary to include nitride compounds into the feedstock. Metallic gallium (or aluminum or indium) can be employed as the source material while the solvent provides the nitrogen required for the nitride formation.
[0054] It has been observed that the solubility of gallium-containing feedstock, such as gallium and corresponding elements of Group XIII and/or their compounds, can be significantly improved by the presence of at least one type of alkali metal-containing component as a solubilization aid (“mineralizer”). Lithium, sodium and potassium are preferred as alkali metals, wherein sodium and potassium are more preferred. The mineralizer can be added to the supercritical solvent in elemental form or preferably in the form of its compound. Generally the choice of the mineralizer depends on the solvent employed in the process. Alkali metal having a smaller ion radius can provide lower solubility than that obtained with alkali metals having a larger ion radius. For example, if the mineralizer is in the form of a compound, it is preferably an alkali metal hydride such as MH, an alkali metal nitride such as M 3 N, an alkali metal amide such as MNH 2 , an alkali metal imide such as M 2 NH or an alkali metal azide such as MN 3 (wherein M is an alkali metal). The concentration of the mineralizer is not particularly restricted and is selected so as to ensure adequate levels of solubility. It is usually in the range of 1:200 to 1:2, in the terms of the mols of the metal ion based on the mols of the solvent (molar ratio). In a preferred embodiment the concentration is from 1:100 to 1:5, more preferably 1:20 to 1:8 mols of the metal ion based on the mols of the solvent.
[0055] The presence of the alkali metal in the process can lead to alkali metal elements in the thus prepared substrates. It is possible that the amount of alkali metal elements is more than about 0.1 ppm, even more than 10 ppm. However, in these amounts the alkali metals do not detrimentally effect the properties of the substrates. It has been found that even at an alkali metal content of 500 ppm, the operational parameters of the substrate according to the invention are still satisfactory.
[0056] In other embodiments, the mineralizer may comprise an ammonium halide, such as NH 4 F, NH 4 Cl, NH 4 Br, or NH 4 I, a gallium halide, such as GaF 3 , GaCl 3 , GaBr 3 , GaI 3 , or any compound that may be formed by reaction of one or more of HF, HCl, HBr, HI, Ga, and NH 3 . The mineralizer may comprise other alkali, alkaline earth, or ammonium salts, other halides, urea, sulfur or a sulfide salt, or phosphorus or a phosphorus-containing salt. A liner or capsule may be used in conjunction with the autoclave to reduce or eliminate corrosion. The mineralizer may be provided as a metal, a loose powder, as granules, or as at least one densified compact or pill.
[0057] The dissolved gallium complexes crystallize in the crystallization step under the low solubility conditions on the crystallization seed(s) which are provided in the container. The process of the invention allows bulk growth of monocrystalline gallium-containing nitride on the crystallization seed(s) and in particular leads to the formation of stoichiometric nitride in the form of a monocrystalline bulk layer on the crystallization seed(s).
[0058] Various crystals can be used as crystallization seeds in the present invention, however, it is preferred that the chemical and crystallographic constitution of the crystallization seeds is similar to those of the desired layer of bulk monocrystalline gallium-containing nitride. Therefore, the crystallization seed preferably comprises a crystalline layer of gallium-containing nitride and optionally one or more other elements of Group XIII. To facilitate crystallization of the etched feedstock, the defects surface density of the crystallization seed is preferably less than 106 cm-2. Suitable crystallization seeds generally have a surface area of 8×8 mm2 or more and thickness of 100 m or more, and can be obtained e.g. by HVPE.
[0059] After the starting materials have been introduced into the container and the nitrogen-containing solvent has been brought into its supercritical state, the gallium-containing feedstock is at least partially etched at a first temperature and a first pressure, e.g. in the etching zone of an autoclave. Gallium-containing nitride crystallizes on the crystallization seed (e.g. in the crystallization zone of an autoclave) at a second temperature and at a second pressure while the nitrogen-containing solvent is in the supercritical state, wherein the second temperature is higher than the first temperature and/or the second pressure is lower than the first pressure, in cases of a negative temperature coefficient for solubility. In cases of a positive temperature coefficient of solubility, the second temperature may be lower than the first temperature. If the etching and the crystallization steps take place simultaneously in the same container, the second pressure is essentially equal to the first pressure.
[0060] This is possible since the solubility under some conditions of the present invention shows a negative temperature coefficient and a positive pressure coefficient in the presence of alkali metal ions. Without wishing to be bound by theory, it is postulated that the following processes occur. In the etching zone, the temperature and pressure are selected such that the gallium-containing feedstock is etched, forming soluble gallium complexes, and the nitrogen-containing solution is undersaturated with respect to gallium-containing nitride. At the crystallization zone, the temperature and pressure are selected such that the solution, although it contains approximately the same concentration of gallium complexes as in the etching zone, is over-saturated with respect to gallium-containing nitride. Therefore, crystallization of gallium-containing nitride on the crystallization seed occurs. Due to the temperature gradient, pressure gradient, concentration gradient, different chemical or physical character of dissolved gallium complexes and crystallized product etc., gallium is transported in a soluble form from the etching zone to the crystallization zone. In the present invention this is referred to as chemical transport of gallium-containing nitride in the supercritical solution. It is postulated that the soluble form of gallium is a gallium complex compound, with Ga atom in the coordination center surrounded by ligands, such as NH 3 molecules or its derivatives, like NH 2 − , NH 2− , etc.
[0061] This theory may be equally applicable for all gallium-containing nitrides, such as AlGaN, InGaN and AlInGaN as well as GaN (the mentioned formulas are only intended to give the components of the nitrides. It is not intended to indicate their relative amounts). In such cases also aluminum and/or indium in a soluble form have to be present in the supercritical solution.
[0062] In a preferred embodiment of the invention, the gallium-containing feedstock is etched in at least two steps. In this embodiment, the gallium-containing feedstock generally comprises two kinds of starting materials which differ in at least one of the kinetics or thermodynamics of etching. A difference in solubility can be achieved chemically (e.g. by selecting two different chemical compounds) or different etching kinetics can be achieved physically (e.g. by selecting two forms of the same compound having definitely different surface areas, like microcrystalline powder and big crystals). In a preferred embodiment, the gallium-containing feedstock comprises two different chemical compounds such as metallic gallium and gallium nitride which etch at different rates. In a first etching step, the first component of the gallium-containing feedstock is substantially or completely etched away at an etching temperature and at an etching pressure in the etching zone. The etching temperature and the etching pressure, which can be set only in the etching zone or preferably in the whole container, are selected so that the second component of the gallium-containing feedstock and the crystallization seed(s) remain substantially unetched. This first etching step results in an undersaturated or at most saturated solution with respect to gallium-containing nitride. For example, the etching temperature can be 100 degrees Celsius to 350 degrees Celsius, preferably from 150 degrees Celsius to 300 degrees Celsius. The etching pressure can be 0.1 kbar to 5 kbar, preferably from 0.1 kbar to 3 kbar. Generally the etching temperature is lower than the first temperature.
[0063] Subsequently the conditions in the crystallization zone are set at a second temperature and at a second pressure so that over-saturation with respect to gallium-containing nitride is obtained and crystallization of gallium-containing nitride occurs on the at least one crystallization seed. Simultaneously the conditions in the etching zone are set at a first temperature and at a first pressure (practically equal to the second pressure) so that the second component of the gallium-containing feedstock is now etched (second etching step). As explained above the second temperature is higher than the first temperature (in the case of a negative temperature coefficient of solubility) and/or the second pressure is lower than the first pressure so that the crystallization can take advantage of the negative temperature coefficient of solubility and/or by means of the positive pressure coefficient of solubility. Preferably the first temperature is also higher than the etching temperature. During the second etching step and the crystallization step, the system should be in a stationary state so that the concentration of gallium in the supercritical solution remains substantially constant, i.e. the same amount of gallium should be etched per unit of time as is crystallized in the same unit of time. This allows for the growth of gallium-containing nitride crystals of especially high quality and large size.
[0064] Typical pressures for the crystallization step and the second etching step are in the range of 1 to 10 kbar, preferably 1 to 5.5 and more preferably 1.5 to 3 kbar. The temperature is in the range of 100 to 800 degrees Celsius, preferably 300 to 600 degrees Celsius, more preferably 400 to 550 degrees Celsius. The difference in temperature should be at least 1 degrees Celsius, and preferably from 5 degrees Celsius to 150 degrees Celsius. As explained above, the temperature difference between the etching zone and crystallization zone should be controlled so as to ensure a chemical transport in the supercritical solution, which takes place through convection in an autoclave.
[0065] In the process of the invention, the crystallization should take place selectively on the crystallization seed and not on a wall of the container. Therefore, the over-saturation extent with respect to the gallium-containing nitride in the supercritical solution in the crystallization zone should be controlled so as to be below the spontaneous crystallization level where crystallization takes place on a wall of the autoclave as well as on the seed, i.e. the level at which spontaneous crystallization occurs. This can be achieved by adjusting the chemical transport rate and the crystallization temperature and/or pressure. The chemical transport is related on the speed of a convection flow from the etching zone to the crystallization zone, which can be controlled by the temperature difference between the etching zone and the crystallization zone, the size of the opening(s) of baffle(s) between the etching zone and the crystallization zone and so on.
[0066] In a specific embodiment, feedstock material can also be prepared using a method similar to those described above. The method involves:
[0000] 1. providing a gallium-containing feedstock, an alkali metal-containing component, at least one crystallization seed and a nitrogen-containing solvent in a container having at least one zone and a basket structure;
2. subsequently bringing the nitrogen-containing solvent into a supercritical state;
3. subsequently etching the gallium-containing feedstock (such as metallic gallium or aluminium or indium, preferably metallic gallium) at an etching temperature and at an etching pressure, whereby the gallium-containing feedstock is substantially completely etched away and the crystallization seed remains substantially unetched so that an undersaturated solution with respect to gallium-containing nitride is obtained; and
4. subsequently setting the conditions in the container at a second temperature and at a second pressure so that over-saturation with respect to gallium-containing nitride is obtained and crystallization of gallium-containing nitride occurs on the at least one crystallization seed.
5. perform other steps, as desired.
[0067] The conditions described above with respect to the etching temperature and the second temperature also apply in this embodiment.
[0068] Gallium-containing nitride exhibits good apparent solubility in supercritical nitrogen-containing solvents (e.g. ammonia), provided alkali metals or their compounds, such as KNH 2 , are introduced into it. FIG. 2 shows the solubility of gallium-containing nitride in a supercritical solvent versus pressure for temperatures of 400 and 500 degrees Celsius wherein the solubility is defined by the molar percentage: S m ≡GaN solvent :(KNH 2 +NH 3 ) 100%. In the presented case the solvent is the KNH 2 solution in supercritical ammonia of a molar ratio x≡KNH 2 :NH 3 equal to 0.07. For this case S m should be a smooth function of only three parameters: temperature, pressure, and molar ratio of mineralizer (i.e. S m =S m (T, p, x)). Small changes of S m can be expressed as: ΔS m ≈(δS m /δT)| p,x ΔT+(δS m /δp)| T,x Δp+(δS m /δx)| T,p Δx, where the partial differentials (e.g. (δS m /δT)| p,x ) determine the behavior of S m with variation of its parameters (e.g. T). In this specification the partial differentials are called “coefficients” (e.g. (δS m /δT)| p,x is a “temperature coefficient of solubility”).
[0069] The diagram shown illustrates that the solubility increases with pressure and decreases with temperature in the presence of alkali-containing mineralizer, which means that it possesses a negative temperature coefficient and a positive pressure coefficient. Such features allow obtaining a bulk monocrystalline gallium-containing nitride by etching in the higher solubility conditions, and crystallization in the lower solubility conditions. In particular, the negative temperature coefficient means that, in the presence of temperature gradient, the chemical transport of gallium in a soluble form can take place from the etching zone having a lower temperature to the crystallization zone having a higher temperature.
[0070] The process according to invention allows the growth of bulk monocrystalline gallium-containing nitride on the seed and leads in particular to creation of stoichiometric gallium nitride, obtained in the form of monocrystalline bulk layer grown on a gallium-nitride seed. Since such a monocrystal is obtained in a supercritical solution that contains ions of alkali metals, it contains also alkali metals in a quantity higher than 0.1 ppm. Because it is desired to maintain a purely basic character of a supercritical solution, mainly in order to avoid corrosion of the apparatus, halides are preferably not intentionally introduced into the solvent. The process of the invention can also provide a bulk monocrystalline gallium nitride in which part of the gallium, e.g. from 0.05 to 0.5 may be substituted by Al and/or In. Moreover, the bulk monocrystalline gallium nitride may be doped with donor and/or acceptor and/or magnetic dopants. These dopants can modify optical, electric and magnetic properties of a gallium-containing nitride. With respect to the other physical properties, the bulk monocrystalline gallium nitride can have a dislocation density below 10 6 cm −2 , preferably below 10 5 cm −2 , or most preferably below 10 4 cm −2 . Besides, the FWHM of the X-ray rocking curve from (0002) plane can be below 600 arcsec, preferably below 300 arcsec, and most preferably below 60 arcsec. The best bulk monocrystalline gallium nitride obtained may have a dislocation density lower than 10 4 cm −2 and simultaneously a FWHM of X-ray rocking curve from (0002) plane below 60 arcsec.
[0071] Due to the good crystalline quality of the obtained gallium-containing nitride crystals obtained in the present invention, they may be used as a substrate material for optoelectronic semiconductor devices based on nitrides, in particular for laser diodes and light emitting diodes.
[0072] In a specific embodiment, a schematic of a frame for seed crystals and raw material is shown in by FIGS. 1A and 1B . The frame enables seed crystals and raw material to be loaded into a suitable configuration for crystal growth prior to placement inside the high pressure apparatus and in a form that is convenient for subsequent handling. The frame should retain good rigidity under crystal growth conditions and be chemically inert to the crystal growth environment, neither contributing contamination to the growing crystals nor undergoing significant corrosion. The materials of construction of the frame and the components thereof may include one or more of copper, copper-based alloy, gold, gold-based alloy, silver, silver-based alloy, palladium, platinum, iridium, ruthenium, rhodium, osmium, titanium, vanadium, chromium, iron, iron-based alloy, nickel, nickel-based alloy, zirconium, niobium, molybdenum, tantalum, tungsten, rhenium, silica, alumina, combinations thereof, and the like. Iron-base alloys that may be used to form the frame include, but are not limited to, stainless steels. Nickel-base alloys that may be used to form the frame include, but are not limited to, inconel, hastelloy, and the like. Again, there can be other variations, modifications, and alternatives. In some embodiments, the components of the frame are fabricated from an alloy comprising at least two elements, for increased hardness and creep resistance. The frame and its components may comprise wire, wire cloth or mesh, foil, plate, sheet, square bar, round bar, rectangular bar, tubing, threaded rod, and fasteners. The frame and its components may be attached by means of welding, arc welding, resistance welding, brazing, clamping, attachment by means of fasteners such as at least one of screws, bolts, threaded rod, and nuts, and the like.
[0073] The frame may include, as components, a baffle, a raw material basket, and a rack for suspending seed crystals, plus a means for attaching at least two of the aforementioned components. In one set of embodiments, illustrated in FIG. 1A , appropriate for the case where the crystal to be grown has a solubility that increases with increasing temperature (i.e., a positive temperature coefficient of solubility), the basket is positioned below the baffle and the seed rack is positioned above the baffle. In another set of embodiments, illustrated in FIG. 1B , appropriate for the case where the crystal to be grown has a solubility that decreases with increasing temperature, i.e., retrograde solubility or a negative temperature coefficient of solubility, the basket is positioned above the baffle and the seed rack is positioned below the baffle. Growth of gallium nitride crystals under ammonobasic conditions normally falls in this category. A larger volume may be provided for the crystal growing region, that is, the region containing the seed rack, than for the nutrient region, that is, the region containing the basket. In one specific embodiment, the ratio of the volumes of the crystal growing region and the nutrient region is between 1 and 5. In other embodiments, this ratio is between 1.25 and 3, or between 1.5 and 2.5. The overall diameter and height of the frame are chosen for a close fit within the high pressure apparatus, so as to maximize the utilization of the available volume and optimize the fluid dynamics. The diameter of the frame may be between 1 inch and 2 inches, between 2 inches and 3 inches, between 3 inches and 4 inches, between 4 inches and 6 inches, between 6 inches and 8 inches, between 8 inches, and 10 inches, between 10 inches and 12 inches, between 12 inches and 16 inches, between 16 inches and 24 inches, or greater than 24 inches. The ratio of the overall height of the frame to its diameter may be between 1 and 2, between 2 and 4, between 4 and 6, between 6 and 8, between 8 and 10, between 10 and 12, between 12 and 15, between 15 and 20, or greater than 20.
[0074] The baffle provides a means for dividing the high pressure apparatus into which the frame is to be inserted into two separate regions, and comprises one or more disks. The two regions are in fluid communication with each other, as baffle has a plurality of through-holes, or openings. Thus, a fraction of the cross-sectional area of the baffle is open. In a specific embodiment, baffle has a fractional open area of between about 0.5% and about 30%, but can also have other percentages. In other embodiments, the baffle has a fraction open area between 2% and 20%, or between 5% and 15%. Baffle serves the purpose of confining the at least one (or more) raw material to a specific region or end of chamber while permitting solvent and, under high pressure high temperature (HPHT) conditions, supercritical fluid, to migrate throughout the high pressure apparatus by passing freely through through-holes in baffle. Often times, this feature is particularly useful in applications such as crystal growth, in which the supercritical fluid transports the at least one material, a nutrient material, from one region of the chamber, defined by placement of baffle, to another region where crystal growth on seed crystals take place. In one specific embodiment, the diameter of the baffle is equal to the maximum diameter of the overall frame. In other embodiments, the diameter of the baffle is slightly less than the maximum diameter of the overall frame, providing an annular space through which fluid can flow under crystal growth conditions. The diameter of the baffle may be less than the maximum diameter of the overall frame by 0.5 inch or less. The openings in the baffle should be large enough so as not to clog readily. In one specific embodiment, the diameters of the openings in the baffle are between 0.020 inch and 0.5 inch. In another embodiment, the diameters of the openings in the baffle are between 0.050 inch and 0.25 inch. In one specific embodiment, the baffle comprises a single disk with a thickness between 0.020 inch and 0.5 inch. In another embodiment, the baffle comprises a single disk with a thickness between 0.050 inch and 0.25 inch. In some embodiments, the baffle comprises two disks, three disks, or more. In some multi-disk embodiments one or more of the openings in the disks lie above one another. In other multi-disk embodiments, one or more of the openings in the disks do not lie above one another. The effective fractional open area in multi-disk baffle embodiments may therefore lie between the fractional open area of each disk, as an upper bound, and the product of the fractional open areas of each disk.
[0075] The raw material basket provides a convenient means for transferring the raw material into the high pressure apparatus, for permitting facile fluid communication from the region between raw material particles within the basket and the crystal growth region, and for removing un-consumed raw material from the reactor at the conclusion of a growth run. In one embodiment, the basket comprises wire mesh or wire cloth, as indicated schematically in the figures. The diameter of the wire in the mesh or cloth may be between 0.001 inch and 0.25 inch, between 0.005 inch and 0.125 inch, or between 0.010 inch and 0.080 inch. The wire mesh or wire cloth may be contained within and, optionally, attached to a frame comprising larger-diameter wire so as to provide improved mechanical support. In another embodiment, the basket comprises foil or plate with a plurality of through-holes or openings. The size of the openings in the wire mesh, wire cloth, or foil or plate should be small enough so that raw material particles do not pass through them during crystal growth, even after a significant portion of the raw material has been etched away and/or consumed by the crystal growth operation. In one specific embodiment, the openings in the wire mesh, wire cloth, or foil or plate have a diameter between 0.005 inch and 0.5 inch. In other embodiments, the openings have a diameter between 0.010 inch and 0.125 inch, or between 0.025 inch and 0.080 inch. In some embodiments, hollow pipes, with openings that are covered by wire mesh, are placed within the basket prior to loading of the raw material so as to improve fluid communication between the region between raw material particles within the basket and the crystal growth region. Suitable configurations for such hollow pipes are described by U.S. Pat. No. 3,245,760, which is hereby incorporated by reference in its entirety, according to a specific embodiment.
[0076] In some embodiments, the raw material is placed in the basket prior to placement of seed crystals on the seed rack, so as to minimize the likelihood of breakage of the latter. The raw material may be supplied in various forms. In some embodiments, the raw material comprises single crystals or chunks or grit of polycrystalline material. In other embodiments, the raw material comprises chunks of sintered polycrystalline material. In the case of gallium nitride, the raw material may be derived from by-product single- or poly-crystalline GaN deposited on the wall or miscellaneous surfaces with a hydride vapor phase epitaxy (HVPE) reactor. In another specific embodiment, the raw material comprises plates of single- or poly-crystalline GaN grown on a substrate by HVPE. In another specific embodiment, the raw material is derived from sintered GaN powder, as described by U.S. Pat. No. 6,861,130, which is hereby incorporated by reference in its entirety. In another specific embodiment, the raw material is derived from polycrystalline GaN plates comprising a columnar microstructure, as described by U.S. Patent Application 2007/0142204A1, which is hereby incorporated by reference in its entirety. The raw material may contain oxygen at a concentration below 10 19 cm −3 , below 10 18 cm −3 , or below 10 17 cm −3 . The raw material may contain an n-type dopant, such as Si or O, a p-type dopant, such as Mg or Zn, a compensatory dopant, such as Fe or Co, or a magnetic dopant, such as Fe, Ni, Co, or Mn, at concentrations between 10 16 cm −3 and 10 21 cm −3 . In one specific embodiment, the particle size distribution of the raw material lies between about 0.020 inch and about 5 inches. In another embodiment, the particle size distribution of the raw material lies between about 0.050 inch and about 0.5 inch. In a preferred embodiment, the total surface area of the raw material is greater, by at least a factor of three, than the total surface area of all the seed crystals that are placed in the seed rack.
[0077] In some embodiments, the raw material comprises a metal that will become molten at elevated temperatures, for example, gallium, indium, sodium, potassium, or lithium. If placed in direct contact with the inner surface of the autoclave or capsule the metal may form an alloy, compromising the integrity of the autoclave or capsule. In some embodiments, therefore, at least one crucible containing at least one metal is placed within or proximate to the raw material basket. The crucible should be chemically inert with respect to the supercritical fluid crystal growth environment and should not react or alloy with the at least one metal. In one specific embodiment, the crucible comprises molybdenum, tantalum, niobium, iridium, platinum, palladium, gold, silver, or tungsten. In another specific embodiment, the crucible comprises alumina, magnesia, calcia, zirconia, yttria, aluminum nitride or gallium nitride. The crucible may comprise a sintered or other polycrystalline material.
[0078] In a preferred embodiment, the seed rack provides a convenient means for transferring the seed crystals or plates into the high pressure apparatus, for permitting facile fluid communication between the seed crystals or plates and the nutrient region on the other side of the baffle, and for removing the grown crystals from the reactor at the conclusion of a growth run. The seed rack should be easy to load and unload, enable efficient usage of the available crystal growth volume, and minimize breakage and other yield losses of the crystals.
[0079] In preferred embodiments, the seed crystals or plates comprise gallium nitride. In other embodiments, the seed crystals or plates may comprise aluminum nitride, sapphire, silicon carbide, MgAl 2 O 4 spinel, zinc oxide, or the like.
[0080] In some embodiments, the frame further comprises a set of stacked disks or baffles on the top end of the frame. The stacked disks or baffles reduce convective heat transfer from the supercritical fluid during crystal growth to the upper end of the autoclave so that the seal of the autoclave may be at a reduced temperature relative to the upper end of the interior of the autoclave. In other embodiments, one or more disks or baffles are placed on top of the frame after insertion of the latter into a high pressure apparatus.
[0081] After loading the frame with seed crystals and raw material, the frame is placed inside a sealable container. The sealable container may constitute an autoclave, an autoclave with a liner, or a capsule designed for use with an autoclave or with an internally-heated high pressure apparatus. At least one mineralizer may be added. The mineralizer may comprise an alkali metal such as Li, Na, K, Rb, or Cs, an alkaline earth metal, such as Mg, Ca, Sr, or Ba, or an alkali or alkaline earth hydride, amide, imide, amido-imide, nitride, or azide. The mineralizer may comprise other alkali, alkaline earth, or ammonium salts, urea, sulfur or a sulfide salt, or phosphorus or a phosphorus-containing salt. The mineralizer may be provided as a loose powder, as granules, or as at least one densified compact or pill. The mineralizer may be added to the raw material basket, may be placed in a crucible, or may be placed directly in the high pressure apparatus or capsule. In a preferred embodiment, the mineralizer is added to the high pressure apparatus or capsule in the absence of exposure to air, such as inside a glove box.
[0082] A getter may also be added to the reaction mix. The getter preferentially reacts with residual or adventitious oxygen or moisture present, improving the purity and transparency of the grown GaN crystals. The getter may comprise at least one of an alkaline earth metal, Sc, Ti, V, Cr, Y, Zr, Nb, Hf, Ta, W, a rare earth metal, and their nitrides, amides, imides, amido-imides, or halides.
[0083] In some embodiments, at least one of the mineralizer and the getter are placed in crucibles within or proximate to the raw material basket.
[0084] The use of metallic precursors for the raw material, mineralizer, and/or getter is convenient in some respects. For example, the metal is typically available commercially in high purity, and no further synthesis is required. However, in addition to the complexity of suitably supporting a metal that melts under reaction conditions (e.g., Ga, Na, K), the use of a pure metal may generate undesirable gases, such as hydrogen. For example, under ammonthermal reaction conditions the metals listed below will undergo one or more of the following reactions:
[0000] Ga+NH 3 =GaN+3/2H 2
[0000] Na+NH 3 =NaNH 2 +½H 2
[0000] K+NH 3 =KNH 2 +½H 2
[0000] Mg+2NH 3 =Mg(NH 2 ) 2 +H 2
[0000] 3Mg+2NH 3 =Mg 3 N 2 +3H 2
[0000] Y+3NH 3 =Y(NH 2 ) 3 +3/2H 2
[0000] Y+NH 3 =YN+3/2H 2
[0085] The presence of hydrogen in the supercritical fluid solvent may decrease the solubility of gallium-containing species and, further, may embrittle the metal constituting the autoclave walls.
[0086] The use of azides as mineralizers is convenient in that they are often available commercially in high purity, can be purified further, and are considerably less hygroscopic than the alkali metals or amides or the alkaline earth nitrides, for example. Use of azide mineralizers is suggested by Dwiliński in U.S. Pat. No. 7,364,619, which is hereby incorporated by reference in its entirety. However, azides typically decompose under reaction conditions, generating undesirable gases, such as nitrogen:
[0000] 3NaN 3 +2NH 3 =3NaNH 2 +4N 2
[0087] In a preferred embodiment, these two effects are combined so as to cancel each other out. Metals, including raw materials, mineralizers, and getters, are added together with azide mineralizer precursors such that H 2 and N 2 are generated in approximately a 3:1 ratio. The reaction container further comprises means for catalyzing NH 3 formation from H 2 and N 2 . Catalysis of the reaction between H 2 and N 2 liberated in the reaction of the metal with ammonia and decomposition of the azide, respectively, to re-form ammonia may be performed by the autoclave walls or by added catalyst. The added catalyst may comprise powder, granules, foil, a coating, bulk material, or a porous pellet. The added catalyst may comprise at least one of iron, cobalt, nickel, titanium, molybdenum, tungsten, aluminum, potassium, cesium, calcium, magnesium, barium, zirconium, osmium, uranium or a lanthanide, ruthenium, platinum, palladium, or rhodium. For example, a mole of added NaN 3 will generate 4/3 mole of N 2 . The latter can be counterbalanced by also adding 8/3 moles of Ga metal, which will generate 8/3×3/2 mole=4 moles of H 2 , viz., three times the number of moles of N 2 from NaN 3 .
[0088] The sealable container is then closed and sealed except for a connection to a gas, liquid, or vacuum manifold. In one embodiment, the high pressure apparatus comprises an autoclave, as described by U.S. Pat. No. 7,335,262, which is hereby incorporated by reference in its entirety. In another embodiment, the sealable container comprises a metal can, as discussed by U.S. Pat. No. 7,125,453, a container, as discussed by U.S. Patent Application No. 2007/0234946, or a capsule, as discussed by U.S. patent application Ser. No. 12/133,365, entitled “Improved capsule for high pressure processing and method of use for supercritical fluids,” all of which are hereby incorporated by reference in their entirety. The inner diameter of the autoclave or capsule may be between 1 inch and 2 inches, between 2 inches and 3 inches, between 3 inches and 4 inches, between 4 inches and 6 inches, between 6 inches and 8 inches, between 8 inches and 10 inches, between 10 inches and 12 inches, between 12 inches and 16 inches, between 16 inches and 24 inches, or greater than 24 inches. The clearance between the inner diameter of the autoclave or capsule and the outer diameter of the frame may be between 0.005 inch and 1 inch, or between 0.010 inch and 0.25 inch. The ratio of the inner height of the autoclave or capsule to its inner diameter may be between 1 and 2, between 2 and 4, between 4 and 6, between 6 and 8, between 8 and 10, between 10 and 12, between 12 and 15, between 15 and 20, or greater than 20.
[0089] After slicing, the crystal wafers may be lapped, polished, and chemical-mechanically polished by methods that are known in the art.
[0090] In a specific embodiment, any of the above sequence of steps provides a method according to an embodiment of the present invention. In a specific embodiment, the present invention provides a method and resulting crystalline material provided by a pressure apparatus having a basket structure. Other alternatives can also be provided where steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
[0091] While the above is a full description of the specific embodiments, various modifications, alternative constructions and equivalents may be used. Therefore, the above description and illustrations should not be taken as limiting the scope of the present invention which is defined by the appended claims. | An apparatus and associated method for large-scale manufacturing of gallium nitride is provided. The apparatus comprises a large diameter autoclave and a raw material basket. Methods include metered addition of dopants in the raw material and control of the atmosphere during crystal growth. The apparatus and methods are scalable up to very large volumes and are cost effective. | 2 |
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates to hydrophilic ethylenically unsaturated macromonomers that are suitable for use in biomedical applications.
BACKGROUND OF THE INVENTION
[0002] The use of polymeric prostheses and biomedical mouldings has grown rapidly in recent times. Such mouldings may be used for contact lenses or for specific ophthalmic purposes. For example, they may be used for intraocular lenses and eye bandages. They may also be used for surgical mouldings such as heart valves and artificial arteries. Other applications include wound dressings, biomedical adhesives and tissue scaffolds. Use in drug delivery is a further application.
[0003] Disease of the lens material of the eye is often in the form of cataracts. The ideal cataract procedure is considered to be one where the lens capsule bag is maintained with the cataractous lens material removed through a small opening in the capsule. The residual lens epithelial cells are removed chemically and/or with ultrasound or lasers. A biocompatible material with appropriate optical clarity, refractive index and mechanical properties is inserted into the capsular bag to restore the qualities of the crystalline lens.
[0004] There have been recent advances in methods of inserting intraocular lens. For example, U.S. Pat. No. 5,772,667 assigned to Pharmacia Lovision Inc, discloses a novel intraocular lens injector. This device compresses an intraocular lens by rolling the lens into a tight spiral. The device injects the compressed lens through a relatively small incision in the eye, approximately 2-3 millimetres in length, resulting from a phacoemulsification procedure. The intraocular lens is inserted into a receiving channel of the injector in an uncompressed state and is urged into a cylindrical passageway. As the intraocular lens advances into the cylindrical passageway, the lens will roll upon itself into a tightly rolled spiral within the confines of the cylindrical passageway. An insertion rod is inserted into an open end of the cylindrical passageway and advances the compressed lens down the passageway. As the lens exits the passageway and enters the eye, the lens will expand back to its uncompressed state.
[0005] To avoid the need for such injection devices, it has been proposed that intraocular lenses be formed in situ after being injected as a liquid flowable form into the lens capsule bag. However, while this concept is attractive in that smaller incisions would be required, it raises further difficulties in that further polymeric reactions are required to take place and these are required to be not harmful to the patient. It is also a requirement that the reaction can take place over a relatively short time under mild reaction conditions. A further requirement is that the reaction is not appreciably inhibited by oxygen. A still further requirement is that no byproducts or residues are produced that are leachable and which may have an adverse biological effect on the patient. It is desirable that the refractive index of the polymer composition for ophthalmic applications is close to 1.41 being the refractive index of the natural biological lens material.
[0006] Patent Application PCT/EP96/00246 in the name of AG Ciba-Geigy discloses water soluble cross-linkable polymers which may be crosslinked in solution to form moulded compositions. These compositions have particular application in contact lenses. The polymers are derivatives of polyvinyl alcohols. A portion of the hydroxyl groups are preferably reacted with 2-vinyl-4,4-dimethylazlactone to produce ethylenically unsaturated macromonomers.
SUMMARY OF THE INVENTION
[0007] This invention provides in one form a hydrophilic ethylenically unsaturated macromonomer comprising units of structure:
where:
m=an integer≧1 n=an integer≧1 r=an integer≧1
[0012] A is a non-reacted moiety resulting from the addition polymerisation of ethylenically unsaturated monomers.
[0013] B is a moiety resulting from the additional polymerisation of ethylenically unsaturated groups that possess hydroxyl or amino groups. Examples of suitable monomers are hydroxybutylacrylate and N hydroxy ethylacrylamide
[0014] C has the following structure:
where:
R 1 =H, Me X=O, NH Z=O, NH, NR, S, CO 2 where R is C 1 -C 8 alkyl W=linear, branched cyclic hydrocarbyl chains, polyether chains or heterochains, linear or cyclic.
[0020] It may include a mixture of moieties resulting from the use of a number of different ethylenically unsaturated monomers. The moieties are “non-reacted”. By “non-reacted” we mean that under the reaction conditions that will allow appropriate side groups to be introduced into the copolymer backbone these “non-reacted” side groups will not form covalent bonds with other groups. Thus by this definition certain chemical groups may be included as being “non-reacted”. The A moiety may be “non-reacted” in that under the reaction conditions side groups will not form covalent bonds. However, the A moiety may also be “non-reacted” because of the stoichiometry of the side groups. Thus it is possible for the A and B moieties to be the same and the A moiety remains unreacted because the number of equivalents of side groups is less than the equivalents of A and B. For example, A may include hydroxybutylacrylate and B may also be hydroxybutylacrylate.
[0021] The balance of the addition copolymer backbone, namely that part of the composition consisting of A and B moieties may be a random or block copolymer.
[0022] Examples of W are polyethylene glycol, polyethylene, cyclic and heterocyclic species such as phenyl rings or piperidine or mixtures of hydrophilic or hydrophobic polymers prepared by processes that allow control over end groups such as chain transfer chemistries and substituted variants thereof.
[0023] C may contain optional groups that are not ethylenically unsaturated polymerisable groups.
[0024] Preferably C is formed by suitable reaction of 2-vinyl-4,4-dimethylazlactone, acryloyl or methacryloyl chloride or related compounds with the complimentary hydroxyl or amino groups on the copolymer backbone. Other methods include suitable reaction of isocyanatoethylmethacrylate, methacrylate anhydride, acrylate anhydride, active esters of acrylates or methacrylates. These can be prepared prior to reaction with the polymer or can be prepared in situ and attached to the copolymer by conventional coupling chemistries, for example the coupling of acrylic acid to alcohol groups on the backbone copolymer using carbodiimide chemistry.
[0025] The macromonomer is hydrophilic. By hydrophilic we mean the macromonomer may be diluted 10% w/w with water without affecting the visual clarity of the macromonomer when viewed through a 100 ml measuring cylinder.
[0026] In an alternative form this invention provides a method of treating presbyopia by removing a patient's lens from the lens capsule bag via an incision in the cornea, injecting into the lens capsule bag a macromonomer of Formula I and wherein the molecular weight of the macromonomer is in the range 10,000-300,000, and wherein the ethylenically unsaturated groups are provided by (meth)acrylamides, (meth)acrylate and styrenic moieties, and polymerising the macromonomer to a polymer having an E modulus in the range 0.01-100 kPa, preferably 0.1-10 kPa, and more preferably 0.5-5 kPa.
[0027] In a further alternative form this invention provides ethylenically unsaturated macromonomers comprising units of Formula I wherein the macromonomer or macromonomer solution has a viscosity at 25° C. in the range 1,000-20,000 cSt, and more preferably 1,000-10,000 cSt and after polymerisation to form biocompatible polymers having an E modulus in the range 0.01-100 kPa, preferably 0.1-10 kPa and more preferably 0.5-5 kPa.
[0028] In a still further embodiment this invention provides a method of preparing intraocular lenses in situ by injecting a flowable macromonomer composition of Formula I where the macromonomer composition has a viscosity at 25° C. in the range 1,000-20,000 cSt, more preferably 1,000-10,000 cSt and after polymerisation having to form a polymer having an E modulus in the range preferably 0.1-10 kPa and more preferably 0.5-5 kPa.
[0029] Preferably in the macromonomer the mole percentage of hydroxyl monomer is in the range 0.5-5% and more preferably 1.0-3.0%.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The preferred scheme of reaction is set out below:
[0031] Acrylamide derivatives are preferred polymerisable groups as these tend to lead to less oxygen inhibition of the composition during crosslinking. This is particularly important for in situ crosslinking as is required when the preferred compositions are used as injectable intraocular compositions.
[0032] Crosslinked gels with different mechanical properties can be produced by irradiation of the macromonomer, depending on the degree of acrylamide functionalised and water content of the macromonomer formulation. The water content is preferably 10-70% w/w and more preferably 20-60%. The elasticity of the cured macromonomer is, as measured by the E modulus, in the range 0.01-100 kPa, preferably 0.1-10 kPa and more preferably 0.5-5 kPa. The E modulus is conveniently measured by equipment such as the Bohlin controlled stress rheometer.
[0033] This crosslinking has the advantage of being rapid and relatively insensitive to inhibition by oxygen.
[0034] The crosslinking process is therefore preferably carried out in such a way that the essentially aqueous solution of the water-soluble polymer comprising crosslinking groups is free or essentially free from undesired constituents, in particular from monomeric, oligomeric or polymeric starting compounds used for the preparation of the water-soluble, cross-linkable polymer, or from by-products formed during the preparation of the water-soluble, cross-linkable polymer, and/or that the solution is used without addition of a comonomer.
[0035] In the case of photo cross-linking, it is expedient to add an initiator which is capable of initiating free-radical crosslinking and is readily soluble in water. Examples thereof are known to the person skilled in the art; suitable photoinitiators which may be mentioned specifically are benzoins, such as benzoin, benzoin ethers, such as benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether and benzoin phenyl ether, and benzoin acetate; acetophenones, such as acetophenone, 2,2-dimethoxyacetophenone and 1,1-dichloroacetophenone; camphorquinone; benzil, benzil ketals, such as benzil dimethyl ketal and benzil diethyl ketal, anthraquinones, such as 2-methylanthraquinone, 2-ethylanthraquinone, 2-tert-butylanthraquinone, 1-chloroanthraquinone and 2-amylanthraquinone; furthermore triphenylphosphine, benzoylphosphine oxides, for example 2,4,6-trimethylbenzoyl-diphenylphosphine oxide, benzophenones, such as benzophenone and 4,4′-bis(N,N-dimethylamino)benzophenone; thioxanthones and xanthones; acridine derivatives; phenazine derivatives; quinoxaline derivatives and 1-phenyl-1,2-propanedione 2-O-benzoyl oxime; 1-aminophenyl ketones and 1-hydroxyphenyl ketones, such as 1-hydroxycyclohexylphenyl ketone, phenyl 1-hydroxyisopropyl ketone, 4-isopropylphenyl 1-hydroxyisopropyl 1-hydroxyisopropyl ketone, 2-hydroxy-1-[-2(-hydroxyethoxy)phenyl]-2-methylpropan-1-one, 1-phenyl-2-hydroxy-2-methylpropan-1-one, and 2,2-dimethoxy-1,2-diphenylethanone, all of which are known compounds.
[0036] Particularly suitable photoinitiators, which are usually used with UV lamps as light sources, are acetophenones, such as 2,2-dialkoxybenzophenones and hydroxyphenyl ketones, in particular the initiators known under the trade names IRGACURE®2959 and DAROCURE®1173.
[0037] Another class of photoinitiators usually employed when argon ion lasers are used are benzil ketals, for example benzil dimethyl ketal.
[0038] The photoinitiators are added in effective amounts, expediently in amounts of from about 0.3 to about 2.0% by weight, in particular from 0.3 to 0.5% by weight, based on the total amount of the water-soluble, cross-linkable polymer.
[0039] The water-soluble, cross-linkable polymers which are suitable in accordance with the invention can be crosslinked by irradiation with ionising or actinic radiation, for example electron beams, X-rays, UV or VIS light, ie electromagnetic radiation or particle radiation having a wavelength in the range from about 280 to 650 nm. Also suitable are UV lamps, He/Dc, argon ion or nitrogen or metal vapour or NdYAG laser beams with multiplied frequency. It is known to the person skilled in the art that each selected light source requires selection and, if necessary, sensitisation of the suitable photoinitiator. It has been recognised that in most cases the depth of penetration of the radiation into the water-soluble, cross-linkable polymer and the rate of curing are in direct correlation with the absorption coefficient and concentration of the photoinitiator.
[0040] If desired, the crosslinking can also be initiated thermally with an appropriate thermal free radical initiator, or by redox processes well known in the art. It should be emphasised that the crosslinking can take place in a very short time in accordance with the invention, for example, in less than five minutes, preferably in less than one minute, in particular in up to 30 seconds, particularly preferably as described in the examples.
[0041] In general hydrophilic copolymers are preferably prepared by standard free radical polymerisation of dimethyl acrylamide with the active hydrogen comonomer, hydroxy butyl acrylate or N-hydroxy ethyl acrylamide, in dioxane to afford white powdery polymers. The feed ratio of monomers is varied to afford a range of copolymers with differing uptake of the hydroxyl monomer into the copolymer.
[0042] The copolymers can then be activated by the 1,8-diazabicyclo[5.4.0]-undec-7-ene (DBU) catalysed condensation in dioxane of 2-Vinyl-4,4-dimethylazlactone with the pendant hydroxy functions of the macromolecules. The resultant acrylamide active macromer is isolated by precipitation, and dried in vacuo at 40° C. for 4 hours. The acrylamide functionalised polymer was then dissolved in an excess of water (ca. 50 wt %) 0.3 wt % of the photoinitiator Irgacure 2959 was added, and then the aqueous solution was evaporated down to the appropriate water content,
[0043] The invention will be further described by reference to preferred embodiments set out in the following examples.
EXAMPLE 1
[0044] This Example illustrates the preparation and testing of a composition according to the present invention.
[0045] A hydrophilic poly(HBA-co-DMA) copolymer was synthesised by dissolving 2.0013 g 4-hydroxybutyl acrylate monomer (Aldrich Cat. No. 27,557-3) and 6.0755 g N,N-dimethylacrylamide monomer (Aldrich Cat. No. 27,413-5) in 120 ml 1,4-dioxane in a 250 ml round bottom flask equipped with a stirrer bar. 0.123 g (1 mole percent) of azobisisobutyronitrile (AIBN) initiator was added, and the monomer solution was freeze-thaw degassed four times. After reaction at 70° C. for 16 hours, the copolymer was isolated by precipitation into hexane, and was dried in vacuo at 40° C. for 4 hours to yield 6.25 g of a white, powdery polymer.
[0046] 1.88 g of the polymer was dissolved in 20 ml 1,4 dioxane in a 50 ml round bottom flask equipped with a stirrer bar and nitrogen purge. 70 milligrams of 1,8-diazabicyclo[5.4.0]-undec-7-ene (DBU) (Aldrich Cat. No. 13,900-9) was added, followed by 0.4801 g 2-vinyl-4,4-dimethylazlactone. The reaction mixture was heated at 70° C. for 17 hours and the polymer was isolated by pouring the reaction mixture into excess hexane. The polymer was then dried in vacuo at 40° C. for 4 hours. The acrylamide functionalised polymer was then dissolved in water to give a 30 wt % solution, and 0.3 wt % of the photoinitiator Irgacure 2959 was added. The polymer solution was placed into polypropylene moulds (designed to give a flat polymeric disc of 20.7 mm diameter and 1.0 mm depth) and polymerised for ten minutes under irradiation from a 365 nm UV lamp. After polymerisation was complete, a transparent, rubbery polymer disc was removed from the moulds. The shear modulus of the polymer was measured with a Bohlin controlled stress rheometer (CS-10) and the results are set out in Table 1.
TABLE 1 DMA/Active Hydrogen Copolymers Polymer Shear Mole % Wt % Viscosity Refractive Modulus Functionalised Solids (cSt) Index (kPa) HBA 1 1 75.9 125,000 1.4389 0.54 2 41.0 850 1.3901 47 3 50.1 14,600 1.4026 90.4 NHEA 2 1.6 65.3 117,000 1.4161 36 1.6 49.0 16,000 1.4014 14.5 1 Hydroxyl butyl acrylate 2 N-hydroxy ethyl acrylamide
EXAMPLES 2 and 3
[0047] These Examples illustrate the preparation and testing of two further compositions according to the present invention.
[0048] Example 1 was repeated except that the solids content was reduced to 25% (Example 2) and 20% (Example 3) to produce the results set out in Table 2.
TABLE 2 Mole % Formulation Shear acrylamide solids content modulus Example functionalised (wt %) (kPa) 2 5 25 16.0 3 5 20 2.1 | A hydrophilic ethylenically unsaturated macromonomer is disclosed that is prepared by the addition polymerization of addition polymerizable monomers that include monomers that have hydroxyl or amino functional groups, some of which may be subsequently reacted to provide (meth)acryl ethylenic unsaturation. The macromonomers may be used to form intraocular lenses in situ by polymerization of the macromonomers, and thus treat presbyopia. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a divisional application of U.S. patent application Ser. No. 12/238,423, filed Sep. 25, 2008, now U.S. Pat. No. 8,023,249, the disclosure of which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a capacitor and a method of manufacturing the same, and more particularly, to increase of capacitance density of a capacitor, improvement of selectivity of dielectric material and electrode metal in constructing the capacitor, and simplification of a manufacturing process of the capacitor.
2. Background Art
Al electrolytic capacitors and multi-layer ceramic capacitors are known and widely used in the art. An Al electrolytic capacitor uses electrolyte and so has a problem in structure for prevention of liquid leakage. A multi-layer ceramic capacitor requires firing and has a problem in design due to variation of a difference in thermal contraction between an electrode and a dielectric substance. Examples of techniques for implementing small and large-capacity capacitors may include a grain boundary-insulated semiconductor ceramic capacitor, which is disclosed in JP-B No. S61-29133 mentioned below, and a capacitor structure body and a method of forming the same, which are disclosed in JP-A No. 2003-249417 mentioned below.
In JP-B No. S61-29133, there is disclosed a grain boundary-insulated semiconductor ceramic capacitor including a grain boundary-insulated semiconductor ceramic having a plurality of through-holes extending opposing sections, external connection electrodes provided in the opposing sections of the grain boundary-insulated semiconductor ceramic, and electrode bodies for capacity which are made of high melting point metal and are inserted in the through-holes of the grain boundary-insulated semiconductor ceramic. The electrode bodies for capacity are conductively connected to the external connection electrodes which are different from each other.
In JP-A No. 2003-249417, there is disclosed an example of a method of forming a capacitor structure body, in which, using a porous substrate obtained by anodizing a substrate, a thin-film forming process is carried out to form a first electrode having a plurality of pillar-shaped bodies on a surface of a substrate for capacitor, a dielectric thin film formed on the surface of the first electrode in such a manner that the dielectric thin film covers the outer side of the pillar-shaped bodies, and a second electrode formed on the surface of the dielectric thin film in such a manner that the second electrode covers the outer side of the pillar-shaped bodies.
[Patent Document 1] JP-B No. S61-29133 [Patent Document 2] JP-A-2003-249417
However, the above related art have the following problems. First, in the technique disclosed in JP-B No. S61-29133 disclosing the structure in which the grain boundary-insulated semiconductor ceramic with the plurality of through-holes is used as a dielectric layer and the capacitive electrode bodies are selectively inserted in the through-holes, it is difficult to achieve large-capacity with increase of an area due to difficulty of micro-processing. In the technique disclosed in JP-A No. 2003-249417, since electrode material is attached to the porous substrate used as the mask and holes are enlarged when the porous substrate is etched, it is difficult to obtain the pillar-shaped bodies having uniform section and desired length. In addition, when the pillar-shaped bodies become lengthened, there may occur variation in film thickness of the dielectric thin film, which makes it difficult to achieve large-capacity with increased height of the pillar-shaped bodies.
SUMMARY OF THE INVENTION
To overcome at least one of the above problems, it is an object of at least one embodiment of the invention to provide a capacitor and a method of manufacturing the same, which are capable of achieving miniaturization and increase of capacitance density of the capacitor, improvement of selectivity of dielectric material and electrode metal in constructing the capacitor, and simplification of a manufacturing process of the capacitor.
To achieve the above object, according to a first aspect of the invention, there is provided a capacitor including: a pair of conductive layers that are opposed to each other at a predetermined interval; a dielectric layer that is interposed between the pair of conductive layers; a plurality of first electrodes that are disposed in some of a plurality of holes passing through the dielectric layer in a direction substantially perpendicular to the pair of conductive layers and that have respective one end portions which are electrically connected to one of the conductive layers and the respective other end portions which are insulated from the other of the conductive layers; and a plurality of second electrodes that are disposed in the remainder of the plurality of holes and that have respective one end portions which are electrically connected to the other of the conductive layers and the respective other end portions which are insulated from the one of the conductive layers. The first electrodes and the second electrodes are randomly distributed.
With this configuration, since the electrodes are formed in the holes passing through the dielectric layer in the thickness direction of the dielectric layer and the first electrodes (for example, positive poles) and the second electrodes (for example, negative poles) are randomly distributed on the conductive layers on the front and rear surfaces of the dielectric layer, it is possible to increase an area defining a capacitance and hence achieve large-capacity of a capacitor.
Preferably, the dielectric layer is made of one of oxide of valve metal, composite oxide and resin. The electrodes are insulated from the conductive layers by cleavages provided between leading ends of at least one of the first and second electrodes and the conductive layers. The electrodes are insulated from the conductive layers by insulators provided between leading ends of at least one of the first and second electrodes and the conductive layers. The insulators are made of one of metal oxide, resin and SiO 2 .
According to a second aspect of the invention, there is provided a method of manufacturing a capacitor including an oxide substrate, which is obtained by anodizing a metal substrate, as a dielectric layer, including: a first step of forming a plurality of first holes, which have a predetermined depth and are filled with electrode material, in one main surface of the oxide substrate in a thickness direction of the oxide substrate by anodizing the metal substrate by applying a voltage to the metal substrate; a second step of forming a plurality of second holes, which have a pitch larger than that of the first holes and are randomly connected to leading ends of some of the first holes, by anodizing the metal substrate by applying a voltage, which is higher than the voltage applied in the first step, to the metal substrate; a third step of opening the leading ends of the second holes at the other main surface of the oxide substrate; a fourth step of forming a conductive seed-layer on the entirety of the one main surface of the oxide substrate; a fifth step of forming first electrodes, which do not reach the leading ends of the first holes, on the seed-layer by filling the first holes connected to the second holes with a conductor; a sixth step of opening end portions of the first holes, in which the first electrodes are not formed, by removing the seed-layer and cutting the other main surface of the oxide substrate by a thickness corresponding to the second holes; a seventh step of forming a conductive layer, which is insulated from the first electrodes, on the entirety of the other main surface of the oxide substrate; an eighth step of forming second electrodes by filling the first holes, in which the first electrodes are not formed, with a conductor in such a manner that the conductor does not reach the one main surface of the oxide substrate with the conductive layer as a seed; and a ninth step of forming another conductive layer, which is connected to the end portions of the first electrodes and is insulated from the second electrodes, on the one main surface of the oxide substrate.
With this configuration, since the structure body of the dielectric layer is first formed and the gap (hole) is later filled with the electrode material, it is possible to improve selectivity of electrode metal and achieve simplification of a manufacturing process.
Preferably, the method further includes at least one of the steps of: preparing an insulator, with which a step with the other main surface of the oxide substrate is filled, on the first electrodes formed in the fifth step; and preparing an insulator, with which a step with the one main surface of the oxide substrate is filled, on the second electrodes formed in the eighth step.
According to a third aspect of the invention, there is provided a method of manufacturing a capacitor, including: a first step of forming a plurality of first holes, which have a predetermined depth and are filled with electrode material, in one main surface of an oxide substrate in a thickness direction of the oxide substrate by anodizing a metal substrate by applying a voltage to the metal substrate; a second step of forming a plurality of second holes, which have a pitch larger than that of the first holes and are randomly connected to leading ends of some of the first holes, by anodizing the metal substrate by applying a voltage, which is higher than the voltage applied in the first step, to the metal substrate; a third step of opening the leading ends of the second holes at the other main surface of the oxide substrate; a fourth step of forming a conductive seed-layer on the entirety of the one main surface of the oxide substrate; a fifth step of forming some of first electrodes on the seed-layer by partially filling the first holes connected to the second holes with a conductor; a sixth step of opening end portions of all of the first holes by cutting the other main surface of the oxide substrate by a thickness corresponding to the second holes: a seventh step of forming the first electrodes, which reach the other end portion of the oxide substrate, which is cut in the sixth step, and second electrodes, which do not reach the cut other end portion, on the seed-layer by filling the plurality of first holes with a conductor; an eighth step of removing the oxide substrate; a ninth step of forming a dielectric layer by filling a gap, which is produced between the first and second electrodes in the eighth step, with a high permittivity material so as to expose end portions of the first electrodes and cover end portions of the second electrodes; a tenth step of forming a conductive layer, which is connected to the end portions of the first electrodes, on a main surface of the dielectric layer opposing the seed-layer and removing the seed-layer from the main surface of the dielectric layer; an eleventh step of forming a step between the end portions of the first electrodes and the main surface of the dielectric layer by cutting the end portions of the first electrodes by a predetermined thickness in the main surface of the dielectric layer from which the seed-layer is removed; and a twelfth step of forming another conductive layer, which is connected to the end portions of the second electrodes and is insulated from the end portions of the first electrodes, on the main surface of the dielectric layer from which the seed-layer is removed.
With this configuration, with the structure body of the oxide substrate, which is made of anodic oxide of metal and has a plurality of holes, as a mold, since the electrodes are formed in the plurality of holes of the dielectric layer while transferring any structure body into the dielectric layer, and the first electrodes (for example, positive poles) and the second electrodes (for example, negative poles) are randomly distributed on the conductive layers on the front and rear surfaces of the dielectric layer, it is possible to increase an area defining a capacitance and hence achieve large-capacity of a capacitor. In addition, since the gap of the structure body of the oxide substrate formed by the anodization is later filled with the electrode material, it is possible to improve selectivity of electrode metal and achieve simplification of a manufacturing process. Further, since the oxide substrate is removed and the gap is filled with any dielectric material, it is possible to improve selectivity of dielectric material and alter dielectric material depending on use of a capacitor.
Preferably, the high permittivity material is one of oxide of valve metal, composite oxide and resin. The high permittivity material is oxide of valve metal which has permittivity higher than that of the removed oxide substrate. The method further includes the step of preparing an insulator, which covers the end portion of the first electrode, in the step formed in the eleventh step. The insulator is made of one of metal oxide, resin and SiO 2 .
According to a fourth aspect of the invention, there is provided a capacitor formed by the method according to the second aspect of the invention. The above and other objects, features and advantages of the disclosed embodiments of the invention will become more fully apparent from the following detailed description and the accompanying drawings.
For purposes of summarizing aspects of the invention and the advantages achieved over the related art, certain objects and advantages of the invention are described in this disclosure. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
Further aspects, features and advantages of this invention will become apparent from the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of this invention will now be described with reference to the drawings of preferred embodiments which are intended to illustrate and not to limit the invention. The drawings are oversimplified for illustrative purposes and are not to scale.
FIG. 1A is a perspective view showing an external appearance of a capacitor element according to Embodiment 1 of the present invention.
FIG. 1B is a sectional view taken along line #A-#A and viewed in an arrow direction in FIG. 1A .
FIG. 1C is a sectional view of a capacitor according to Embodiment 1, which is taken along line #B-#B and viewed in an arrow direction in FIG. 1A .
FIGS. 2A to 2G are views showing an exemplary manufacturing process of Embodiment 1.
FIGS. 3A to 3E are views showing another exemplary manufacturing process of Embodiment 1.
FIGS. 4A to 4C are views showing still another exemplary manufacturing process of Embodiment 1.
FIG. 5 shows a SEM image having a two dimensional section observed in the course of manufacturing the capacitor element of Embodiment 1.
FIG. 6 is a perspective view showing an external appearance of a capacitor element according to Embodiment 2 of the present invention.
FIGS. 7A to 7E are views showing an exemplary manufacturing process of Embodiment 2.
FIGS. 8A to 8E are views showing another exemplary manufacturing process of Embodiment 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, preferred embodiments of the present invention will be described in detail. The preferred embodiments are not intended to limit the present invention.
In the present disclosure where conditions and/or structures are not specified, the skilled artisan in the art can readily provide such conditions and/or structures, in view of the present disclosure, as a matter of routine experimentation. Further, the anodic oxidation technology disclosed in U.S. patent application Ser. No. 12/139,444, filed Jun. 13, 2008, now U.S. Pat. No. 8,064,189 and U.S. patent application Ser. No. 12/139,450, filed Jun. 13, 2008, now U.S. Pat. No. 8,134,826, by the same assignee as in the present application can be used and modified, the disclosure of which is herein incorporated by reference in their entirety.
The present invention will be explained in detail with reference to specific examples which are not intended to limit the present invention. The numerical numbers applied in specific examples may be modified by a range of at least ±50%, wherein the endpoints of the ranges may be included or excluded.
Embodiment 1
First, Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 5 . FIG. 1A is a perspective view showing an external appearance of a capacitor element according to Embodiment 1, FIG. 1B is a sectional view taken along line #A-#A and viewed in an arrow direction in FIG. 1A , and FIG. 1C is a sectional view of a capacitor according to Embodiment 1, which is taken along line #B-#B and viewed in an arrow direction in FIG. 1A . FIGS. 2 to 4 are views showing exemplary manufacturing processes of Embodiment 1, and FIG. 5 shows a SEM image having a two dimensional section observed in the course of manufacturing the capacitor element of Embodiment 1.
A capacitor 10 of this embodiment is configured with a capacitor element 2 as a main component, as shown in FIG. 1 . The capacitor element 12 includes a pair of conductive layers 14 and 16 which are opposed to each other at a predetermined interval, a dielectric layer 18 interposed between the conductive layers 14 and 16 , and a plurality of first electrodes 20 and second electrodes 24 . The first electrodes 20 and the second electrodes 24 are substantially perpendicular to the conductive layers 14 and 16 and have a large aspect ratio. One end portion 20 A of each of the first electrodes 20 is connected to the conductive layer 14 and the other end portion 20 B is insulated from the conductive layer 16 by an insulation cap 22 . One end portion 24 B of each of the second electrodes 24 is connected to the conductive layer 16 and the other end portion 24 A is insulated from the conductive layer 14 by an insulation cap 26 . The first electrodes 20 and the second electrodes 24 are randomly arranged, as shown in FIG. 1B .
Materials used to form the dielectric layer 18 may include oxides of valve metal (for example, Al, Ta, Nb, Ti, Zr, Hf, Zn, W, Sb, etc.). The conductive layers 14 and 16 may be made of general metal (for example, Cu, Ni, Cr, Ag, Au, Pd, Fe, Sn, Pb, Pt, Ir, Rh, Ru, Al, etc.). The first electrodes 20 and the second electrodes 24 may be made of platable general metal (for example, Cu, Ni, Co, Cr, Ag, Au, Pd, Fe, Sn, Pb, Pt, etc.) and alloys thereof. The insulation caps 22 and 26 may be made of, for example, oxides of valve metal (for example, Al, Ta, Nb, Ti, Zr, Hf, Zn, W, Sb, etc.), electrodeposited TiO 2 , electrodeposited resin (for example, polyimide, epoxy, acryl, etc.), SiO 2 , etc.
As examples of dimension for the components of the capacitor element 12 , an interval between the conductive layer 14 and the conductive layer 16 (i.e., thickness of the dielectric layer 18 ) is several 100 nm to several 100 μm and thickness of each of the conductive layer 14 and 16 is several 10 nm to several μm. Diameter of each of the first electrodes 20 and second electrodes 24 is several 10 nm to several 100 nm, and length thereof is several 100 nm to several 100 μm, and an interval between adjacent electrodes is several 10 nm to several 100 nm. In addition, thickness of each of the insulation caps 22 and 26 is several 10 nm to several 10 μm.
The capacitor element 12 as constructed above is entirely coated with an insulating film 30 (exterior protective material) and is connected from openings, which are provided in predetermined positions of the insulating film 30 , to leading portions 36 and 38 such as lead wires via connected lands 32 and 34 , as shown in FIG. 1C . The insulating film 30 may be made of, for example, SiO 2 , SiN, resin, metal oxide, etc., and its thickness is several 10 nm to several 10 μm.
Next, a method of manufacturing the capacitor 10 according to this embodiment will be described with reference to FIGS. 2 to 4 . First, a metallic substrate 50 made of the above-mentioned valve metal is prepared, as shown in FIG. 2A , and then pits 52 , which become starting points of anodic oxidation, are formed in closest packing hexagonal array on a surface 50 A of the metallic substrate 50 , as shown in FIG. 2B . Next, first holes 54 are formed at desired depth (or length) in a thickness direction of the metallic substrate 50 by subjecting the metallic substrate 50 to anodization under application of a voltage to the metallic substrate 50 , as shown in FIG. 2C . Subsequently, second holes 56 are formed by subjecting the metallic substrate 50 to anodization under application of a voltage, which is lager than the voltage applied for the first holes 54 , to the metallic substrate 50 , thereby completing the dielectric layer 18 constituted by an oxide substrate 53 , as shown in FIG. 2D . Since a pitch of the holes (an interval between the holes) formed by the anodization is proportional to a voltage, a pitch of the second holes 56 formed under a larger voltage become large and accordingly are randomly connected to some of the first holes 54 formed in the previous process.
In connection with the anodization, the first anodization shown in FIG. 2C is carried out under conditions of application voltage of several V to several 100 V and processing time of several minutes to several days, and the second anodization shown in FIG. 2D is carried out under conditions of application voltage, which is several times (e.g., 2-5 times) as large as the first application voltage and processing time of several minutes to several tens minutes (which is shorter than that of the first anodization). For example, the first holes 54 are formed at diameter of about 30 nm (typically 30 nm to 40 nm) if the first application voltage is 40V, while the second holes 56 are formed at diameter of about 70 nm (typically 60 nm to 80 nm) if the second application voltage is 80V. When the second application voltage falls within the above-mentioned range, the number of first holes 54 connected to the second holes 56 may become substantially equal to the number of first holes 54 not connected to the second holes 56 . Accordingly, the number of first electrodes 20 formed within the first holes 54 connected to the second holes 56 may become substantially equal to the number of second electrodes 24 formed within the first holes 54 not connected to the second holes 56 , thereby making it possible to take out capacity of the capacitor with efficiency. In addition, when the second processing time falls within the above-mentioned range, sufficient transformation of the pitch of the holes can be achieved to decrease thickness of the oxide substrate formed in the second anodization. Since the oxide substrate formed in the second anodization is removed in a later process, it is preferably as thin as possible (typically 50 nm to 5 μm). The thickness of the oxide substrate formed in the first anodization may be 100 nm to 1000 μm in an embodiment.
Next, under the condition shown in FIG. 2D , a base metal portion of the metallic substrate 50 is removed, the dielectric layer 18 is cut away by a predetermined thickness, as shown in FIG. 2E , and end portions of the second holes 56 are opened in a rear surface 18 B of the dielectric layer 18 , as shown in FIG. 2F . Then, as shown in FIG. 2G , a seed-layer 58 made of a conductor is formed on a front surface 18 A of the dielectric layer 18 by an appropriate method such as PVD or the like. Next, as shown in FIG. 3A , the first electrodes 20 are formed by filling the first holes 54 , which are connected to the second holes 56 , with a plating conductor, using the seed-layer 58 as a seed. At this point, since the end portions of the first holes 54 not connected to the second holes 56 are opened, the first holes 54 not connected to the second holes 56 are not filled with the plating conductor. The filling of the plating conductor is carried out up to a position where the end portions 20 B of the first electrodes 20 form appropriate cleavages 60 without extending to the second holes 56 . Then, as shown in FIG. 3B , the insulating caps 22 are formed in the cleavages 60 by an appropriate method such as anodization, oxide electrodeposition, resin electrodeposition or the like.
FIG. 5 shows a SEM image having a two dimensional section observed after the process shown in FIG. 3A . In FIG. 5 , white portions indicate first holes 54 filled with a plating conductor (Ni and the like), black portions indicate first holes 54 not filled with a plating conductor, and gray portions indicate the dielectric layer 18 (or the oxide substrate 53 ). As can be seen from FIG. 5 , the holes 54 filled with the plating conductor and the holes 54 not filled with the plating conductor are randomly distributed with no partiality.
Next, as shown in FIG. 3C , the seed-layer 58 is removed, and then the rear surface 18 B of the dielectric layer 18 is cut away by a thickness corresponding to the second holes 56 , as indicated by a dotted line in this figure, so that the end portions 54 B of the first holes 54 in which the first electrodes 20 are not formed, are opened, as shown in FIG. 3D . Then, as shown in FIG. 3E , the conductive layer 16 is formed in the rear surface 18 B of the dielectric layer 18 by an appropriate method such as PVD or the like, and then, as shown in FIG. 4A , the second electrodes 24 are formed by filling the first holes 54 , in which the first electrodes 20 are not formed, with a plating conductor, using the conductive layer 16 as a seed. At this point, the filling of the plating conductor is carried out up to a position where the end portions 24 A of the second electrodes 24 form appropriate cleavages 62 between the end portions 24 A and the front surface 18 A of the dielectric layer 18 . Then, as shown in FIG. 4B , the insulating caps 26 are formed in the cleavages 62 by an appropriate method such as anodization, oxide electrodeposition, resin electrodeposition or the like. Thereafter, as shown in FIG. 4C , the conductive layer 14 is formed on the front surface 18 A of the dielectric layer 18 , thereby completing the capacitor element 12 in which the first electrodes 20 are electrically connected to the conductive layer 14 and the second electrodes 24 are electrically connected the conductive layer 16 .
With the above-described configuration and operation, Embodiment 1 has the following effects.
(1) Since the first electrodes 20 and the second electrodes 24 are formed into a substantially pillar-shape to increase an opposing area of a conductor, it is possible to achieve large capacity of the capacitor.
(2) Since the first electrodes 20 and the second electrodes 24 are randomly distributed, it is easy to manufacture these electrodes. For example, if either the first electrodes 20 or the second electrodes 24 are arranged at vertexes of hexagonal honeycomb structures and the other electrodes are arranged at centers of the hexagonal honeycomb structures, even when holes are to be lengthened to fill these electrodes, since a difference in growth between the holes is vanished, it is difficult to manufacture these electrodes. However, in this embodiment, the pillar-shaped electrodes can be lengthened by employing the above-described two-staged anodizations.
(3) Since the insulating caps 22 and 26 are used for random distribution of the electrodes, the area of the end portions 20 B of the first electrodes 20 and the area of the end portions 24 A of the second electrodes 24 can be also used for increase of the capacity of the capacitor 10 .
(4) Since the first holes 54 are filled with the first electrodes 20 and the second electrodes 24 after the first holes 54 are formed in the dielectric layer 18 constituted by the oxide substrate 53 , it is possible to improve selectivity of electrode material and simplify a manufacturing process.
Embodiment 2
Next, Embodiment 2 of the present invention will be described with reference to FIGS. 6 to 8 . FIG. 6 is a perspective view showing an external appearance of a capacitor element according to this embodiment, and FIGS. 7 to 8 are views showing exemplary manufacturing processes of this embodiment. In these figures, the same components as Embodiment 1 are denoted by the same reference numerals. As shown in FIG. 6 , a capacitor element 100 of this embodiment includes a pair of opposing conductive layers 102 and 104 , a dielectric layer 106 which is made of high permittivity material and is interposed between the pair of conductive layers 102 and 104 , and a plurality of first electrodes 108 and second electrodes 112 with which a plurality of holes formed in the dielectric layer 106 are filled.
The first electrodes 108 and the second electrodes 112 are randomly distributed like Embodiment 1. An insulation cap 110 is formed between one end portion 108 A of each of the first electrode 108 and the conductive layer 102 and the dielectric layer 106 interposed between one end portion 112 B of each of the second electrode 112 and the conductive layer 104 . In this manner, the insulation caps 110 and the dielectric layer 106 insulate the first electrodes 108 and the second electrodes 112 from the conductive layers 102 and 104 , thereby providing random distribution of the electrodes. The capacitor element 100 of this embodiment is coated with an insulating film (exterior protective material (not shown)) if necessary, like Embodiment 1. The dimension of components of the capacitor element 100 is the same as the dimension in Embodiment 1.
Material used for the conductive layers 102 and 104 , the first electrodes 108 , the second electrodes 112 and the insulating film is the same as that in Embodiment 1. An example of the high permittivity material used to form the dielectric layer 106 may include oxide of valve metal (for example, Al, Ta, Nb, Ti, Zr, Hf, Zn, W, Sb, etc.), for example, Ta 2 O 5 (25), TiO 2 (80), Nb 2 O 5 (60), ZrO 2 (27), HfO 2 (25) or the like (numbers in parentheses indicate permittivity), composite oxide (for example, Ba x Sr 1-x ) TiO 3 (300 to 1200), SrTiO 3 (300), resin or the like. The insulation caps 110 may be made of metal oxide, electrodeposition resin (for example, polyimide, epoxy, acryl or the like), SiO 2 , etc. The metal oxide may include, for example, oxide of valve metal (Al, Ta, Nb, Ti, Zr, Hf, Zn, W, Sb, etc.), electrodeposited TiO 2 , composite oxide having an ABO 3 structure, etc. In addition, the insulation caps 110 may be formed by the same material as the dielectric layer 106 .
Next, a manufacturing method of this embodiment will be described with reference to FIGS. 7 and 8 . This manufacturing method includes two-staged anodization for a metallic substrate and processes of opening the second holes 56 in the rear surface 53 B of the oxide substrate 53 and forming the seed-layer 58 on the front surface 53 A of the metallic substrate 53 , like Embodiment 1 mentioned above. FIG. 7 shows processes subsequent to the processes in Embodiment 1. After the processes of FIGS. 2A to 2G , as shown in FIG. 7A , a part of the first electrodes 108 is formed by filling the first holes 54 connected to the second holes 56 with a plating conductor halfway, with the seed-layer 58 , which is formed on the front surface 53 A of the oxide substrate 53 , as a seed. After forming the part of the first electrodes 108 , the filling of the conductor is stopped, the rear surface 53 B of the oxide substrate is cut away by a thickness corresponding to the second holes 56 , as indicated by a dotted line in FIG. 7A , and then, the end portions 54 B of the first holes 54 are opened, as shown in FIG. 7B .
Subsequently, using the seed-layer 58 as a seed, a plating process is carried out to fill all of the first holes 54 with a plating conductor, thereby forming the first electrodes 108 and the second electrodes 112 , as shown in FIG. 7C . The filling of the plating conductor is carried out until the end portions 108 B of the first electrodes 108 reach the rear surface 53 B of the oxide substrate 53 . Since the first electrodes 108 have been partially formed in the previous process, there is a difference in length between the first electrodes 108 and the second electrodes 112 . When the filling of the conductor is stopped at an earlier point when the end portions 108 B of the first electrodes 108 reach the rear surface 53 B of the oxide substrate, the end portions 112 B of the second electrodes 112 do not reach the rear surface 53 B of the oxide substrate, thereby forming a cleavage 64 .
Next, with the first electrodes 108 and the second electrodes 112 left, the oxide substrate 53 is removed, as shown in FIG. 7D , and the dielectric layer 106 is formed by filling a gap 66 with high permittivity material, as shown in FIG. 7E . The oxide substrate 53 is removed by, for example, etching. If the oxide substrate 53 is made of Al 2 O 3 and the first electrodes 108 and the second electrodes 112 are made of Ni, it is possible to remove only Al 2 O 3 under a process by a NaOH solution. The filling of the high permittivity material is carried out by, for example, a CVD method, a sol-gel method or the like. The gap 66 is filled with the high permittivity material in such a manner that the high permittivity material covers the end portions 112 B of the second electrodes 112 while exposing the end portions 108 B of the first electrodes 108 . Next, the seed-layer 58 is removed, as shown in FIG. 8A , the conductive layer 104 is formed on the rear surface 106 B of the dielectric layer 106 at a side opposing the seed-layer 58 , as shown in FIG. 8B . While the conductive layer 104 is connected to the end portions 108 B of the first electrodes 108 , it is insulated from the end portions 112 B of the second electrodes 112 by the existence of the dielectric layer 106 .
Subsequently, an electrolytic etching is carried out with the conductive layer 106 as a feeding power layer, and the other end portions 108 A of the first electrodes 108 are selectively etched to form steps 68 between the end portions 108 A and the front surface 106 A of the dielectric layer 106 , as shown in FIG. 8C . Then, the insulation caps 110 are formed in the steps 68 by an appropriate method such as anodization, oxide electrodeposition, resin electrodeposition or the like, as shown in FIG. 8D , and then, the conductive layer 102 is formed on a surface of the insulation caps 110 by an appropriate method such as PVD or the like, as shown in FIG. 8E . While the conductive layer 102 is connected to the end portions 112 A of the second electrodes 112 , it is insulated from the end portions 108 A of the first electrodes 108 by the existence of the insulation caps 110 .
With the above-described configuration and operation, Embodiment 2 has the following effects in addition to the effects of Embodiment 1.
(1) Since the dielectric layer 106 is made of the high permittivity material, it is possible to achieve large-capacity of the capacitor. For example, if the oxide substrate 53 is made of Al 2 O 3 having permittivity of 10 or so and is used as a capacitive material, the capacitance of the capacitor is defined by Al 2 O 3 , while, in this embodiment, the holes are filled with the material having permittivity higher than that of the oxide substrate 53 , thereby making it possible to form a capacitor having permittivity higher than that of the oxide substrate 53 used as a mold.
(2) Since the oxide substrate 53 is removed after forming the first electrodes 108 and the second electrodes 112 and then the gap 66 is filled with the high permittivity material, it is possible to improve selectivity of material for the dielectric layer 106 and change dielectric material depending on use of capacitors.
The present invention is not limited to the above-described embodiments but may be modified in different ways without departing from the spirit and scope of the present invention. For example, the skilled artisan would understand that the disclosed embodiments can be modified as follows, for example.
(1) The shape and dimension shown and described in the above embodiments are only for the purpose of illustration and may be modified where appropriate or if necessary.
(2) The material described in the above embodiments is also for the purpose of illustration and may be any material known in the art. For example, although aluminum is used for the metallic substrate used for forming the dielectric layer 18 , any other metal known in the art may be applied as long as it can be anodized.
(3) The electrode leading structure described in Embodiment 1 is also for the purpose of illustration and may be appropriately modified in design to show the same effects.
(4) The manufacturing processes described in the above embodiments are also for the purpose of illustration and may be appropriately modified to show the same effects. For example, which to form first, the front surface or the rear surface, depends on use and need.
(5) Although the insulation is achieved by the insulation caps 22 and 26 in Embodiment 1, this is also for the purpose of illustration. The conductive layer 16 may be directly formed in the processes shown in FIGS. 3C to 3E after the process shown in FIG. 3A with omission of the process shown in FIG. 3B , and may be insulated from the first electrodes 20 using the cleavage 60 formed in the process of FIG. 3A as an air-gap. Also for the insulation of the second electrodes 24 from the conductive layer 14 or Embodiment 2, the electrodes may be randomly distributed using such an air-gap.
Although the insulation caps 22 , 26 and 110 are formed by the anodization, the oxide electrodeposition or the resin electrodeposition in the above embodiments, this is also for the purpose of illustration and may be modified to show the same effects. For example, after the process shown in FIG. 3A , SiO 2 may be electrodeposited through the first electrodes 20 exposed to the bottom of the cleavage 60 , or once catalyst metal such as Sn—Pd is electrodeposited on the electrode end portions 20 B, SiO 2 may be precipitated by electroless based on this electrodeposition. In addition, resin may be coated to fill the cleavage 60 and only resin on a surface may be removed by etching or polishing such that resin is left in the cleavage 60 . In addition, insulator may be formed to fill the cleavage 60 and only insulator on a surface may be removed by etching or polishing such that insulator is left in the cleavage 60 . This may be true of the other insulation cap 26 or embodiment 2.
According to at least one embodiment of the present invention, since (1) the electrodes are formed in the holes passing through the dielectric layer in the thickness direction and the first electrodes (for example, positive poles) and the second electrodes (for example, negative poles) are randomly distributed on the conductive layers on the front and rear surfaces of the dielectric layer, or (2) with a structure body of the oxide substrate, which is made of anodic oxide of metal and has a plurality of holes, as a mold, the electrodes are formed in the plurality of holes of the dielectric layer while transferring the structure body into the dielectric layer, and the first electrodes (for example, positive poles) and the second electrodes (for example, negative poles) are randomly distributed on the conductive layers on the front and rear surfaces of the dielectric layer, the present invention can be effectively applied to any capacitors.
The present application claims priority to Japanese Patent Application No. 2007-252782, filed Sep. 27, 2007, the disclosure of which is incorporated herein by reference in its entirety.
It will be understood by those of skill in the art that numerous and various modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the forms of the present invention are illustrative only and are not intended to limit the scope of the present invention. | A method of manufacturing a capacitor includes: anodizing a metal substrate in two stages by applying two different voltage so as to make first and second holes having different pitches, distributed randomly in an oxide substance; filling the first and second holes with an electrode material, respectively, to form first and second electrodes; connecting the first electrodes to a conductive layer formed on one surface of the oxide substance; and connecting the second electrodes to another conductive layer formed on another surface of the oxide substance. | 7 |
BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] This invention relates generally to electrosurgical instruments, and more particularly to an improved, bipolar, hook-probe for use in endoscopic surgery to provide enhanced cutting and coagulation capability over existing hook-probe instruments.
[0003] II. Discussion of the Prior Art
[0004] In the course of minimally invasive procedures, electrosurgery is often employed to effect cutting and coagulation or cauterization of tissue structures. The electrosurgical instruments employed have one or more electrodes adapted to be energized by RF currents. In so-called monopolar systems, the current passes from the instrument, through the tissue to be cut or coagulated to a body plate type return electrode located remote from the surgical site. Since the electrical currents tend to follow a path of least resistance from the instrument to the return electrode, the path is somewhat unpredictable and it has led to burns at unintended locations.
[0005] In the case of bipolar instruments, the active electrode and the associated return electrode are disposed in close proximity to one another on the instrument itself so that there is less likelihood of current flow to tissues other than intended tissue structures being operated upon. Bipolar electrosurgery is considered by most as a safer procedure.
[0006] In the Fleenor et al. U.S. Pat. No. 5,484,435, there is described a bipolar electrosurgical instrument intended for use in minimally invasive surgical procedures for both cutting and coagulating tissue, thus obviating the need for an instrument exchange where separate instruments as required for the cutting and coagulating functions. The instrument described in the '435 patent comprises a handle 98 disposed at one end of an elongated tubular barrel 96 having as one electrode a hook 90 in the form of a bent uninsulated wire and a one-piece return electrode 92 that is somewhat hemispherical in shape that projects outwardly from the distal end of the barrel and which has a slot formed therein for receiving the hook electrode therethrough. The walls of the slot are insulated so as to prevent short-circuiting with the hook member electrode but the portions of the electrode 92 on both sides of the slot are not insulated from each other. A lever assembly 98 on the handle, which when manipulated, allows the active hook electrode 90 to be extended and retracted relative to the fixed return electrode 92 . In use, the active hook electrode is made to frictionally engage or slightly puncture target tissue to grip it. Then, by manipulating the lever 98 on the handle, the tissue can be drawn proximally to engage the return electrode. The electrosurgical generator is then activated to achieve cutting or coagulation.
[0007] The device of the '435 patent achieves acceptable levels of cutting because of the high current density present due to the small size and shape of the active electrode. However, coagulation with that instrument leaves much to be desired, given the small electrode surface area of the active electrode compared to that of the one-piece return electrode 92 .
[0008] Bipolar coagulation devices require equal electrode surface area or a ratio of 1:1 for optimum results. Bipolar cut devices require a 4:1 or greater return electrode to active electrode ratio for effective precision cutting. Prior art bipolar devices have tended to be either good coagulators or good cutters, but not both.
[0009] The present invention is deemed to be a substantial improvement over the prior art as represented by the Fleenor et al. '435 patent. The device constructed in accordance with the present invention provides a hook probe that not only effectively cuts target tissue, but it also provides superior coagulation.
[0010] The Rydell U.S. Pat. No. 5,282,799 in the embodiment illustrated in FIG. 9 discloses an arrangement in which a pair of loop electrodes 28 and 30 are mounted on the distal end of a reciprocally movable control rod 60 that can be shifted longitudinally, via a thumb slide 224 so as to be extended from the distal tip of the instrument or retracted fully within the distal tip of the instrument. Also present on the insulating distal tip member 70 of the instrument are electrode surfaces 71 and 73 . A push-button 216 moves longitudinally with the control rod so as to overlay a first dome switch 210 or a second dome switch 212 . When the loop electrodes 28 and 30 are in their distalmost position projecting from the distal end of the instrument, the push-button 216 overlays the dome switch 210 . Thus, when the push-button 216 is depressed, a cutting potential is applied between the electrodes 28 and 30 . When the loop electrodes 28 and 30 are retracted by shifting the thumb slot in the proximal direction, the push-button 216 overlays the dome switch 212 so when it is depressed, a coagulating voltage is applied to the electrodes. Since the loop electrodes are retracted into a recess in the distal tip, they are not exposed to tissue. Only tissue bridging the surface contacts 71 and 73 will have a coagulating current flowing through it.
[0011] In this design, when electrosurgical cutting is involved, the same cutting voltage that is applied to the loop electrodes 28 and 30 is also present between the surface-mounted coagulating electrodes 71 and 73 . The surgeon must, therefore, exercise increased caution to avoid inadvertent contact of non-target tissue with the surface electrodes as the cutting operation is taken place.
[0012] The Rydell U.S. Pat. No. 5,891,141 describes an electrosurgical instrument for cutting and coagulating tubular tissue structures, such as vein and arterial tissue, by grasping the tissue between a pair of spaced-apart electrodes that when energized by RF energy coagulates the portion of the tissue structure contained between the two electrodes. Once desiccated, a thumb switch is manipulated to cause a cutting blade to mechanically cut through the desiccated tissue.
[0013] The Roos U.S. Pat. No. 5,269,780 describes an electrosurgical instrument designed to both cut and coagulate tissue. It includes a handle having a pair of stationary L-shaped hook electrodes 22 and 23 projecting from a distal end of the handle in parallel, spaced-apart relation. These electrodes function to coagulate tissue and once coagulated, a cutting electrode 21 is made to descend into the gap between the two stationary electrodes while a cutting voltage is applied between it and the two stationary coagulating electrodes which function as a neutral. No provision is made for retracting any of electrodes 21 - 23 into the handle member.
SUMMARY OF THE INVENTION
[0014] The foregoing objects and advantages of the present invention are provided by designing a bipolar electrosurgical cutting and coagulating probe that has an elongated, tubular barrel with a proximal end, a distal end and a lumen extending between the two. A handle member is affixed to the proximal end of the barrel and an end effector is affixed to its distal end. The end effector in accordance with the present invention includes first and second electrodes that are placed in parallel, closely-spaced, non-contacting relationship where each is of a relatively large surface area. A conductive, reciprocally movable hook member is operatively coupled to a mechanism on the handle member so that manipulation of the mechanism causes the hook member to be movable in and out of the space separating the first and second electrodes from one another. The hook member has a relatively small surface area compared to the combined surface area of the first and second electrodes. A plurality of elongated conductors extends through the handle and into the lumen of the barrel, the first being electrically connected to the first electrode, the second to the second electrode and the third to the hook member electrode. In its cut mode, an appropriate RF voltage is applied between the hook electrode and the first and second electrodes as tissue comes into contact with all three electrodes or is gripped by the hook drawn toward and against the first and second electrodes which together function as the return electrode for the bipolar instrument. When operating in a coagulation mode, however, the RF voltage is only applied between the first and second electrodes. The hook is not energized. Because the first and second electrodes are of generally equal surface area, coagulation occurs over the entire active surfaces of the first and second electrodes, providing appreciably greater margins than result from the Fleenor-type instrument,
[0015] There are, of course, additional features of the invention that will be described hereinafter which will form the subject matter of the appended claims. Those skilled in the art will appreciate that the preferred embodiments may readily be used as a basis for designing other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions since they do not depart from the spirit and scope of the present invention. The foregoing and other features and other advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a partial side elevation view of the bipolar electrosurgical hook probe comprising a preferred embodiment of the invention;
[0017] [0017]FIG. 2A is a partial view of the distal end portion of the instrument of FIG. 1 with the hook member extended;
[0018] [0018]FIG. 2B is a partial view of the distal end portion of the instrument; and
[0019] [0019]FIG. 3 illustrates a switching circuit for selecting either the cut mode or the coagulation mode of operation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring first to FIG. 1, there is indicated generally by numeral 10 a bipolar electrosurgical hook probe instrument embodying the present invention. It is seen to comprise an elongated tubular barrel 12 whose outside diameter is dimensioned so as to pass through a viewing endoscope or a trocar when used in a minimally invasive surgical procedure. The barrel 12 has a proximal end 14 and a distal end 16 along with a lumen 18 extending therebetween. The tubular barrel 12 may comprise an extruded metal tube of a predetermined length having an electrically insulating coating on its exterior surface. Alternatively, the tubular barrel 12 may be formed from a suitable plastic in an extrusion operation.
[0021] Affixed to the proximal end 14 of the tubular barrel 12 is a handle member 20 that is generally longitudinally aligned with the barrel. The handle 20 is ergonomically designed to be grasped with the curved bottom surface 22 lying generally across the joints between the metacarpals and proximal phalanges of a surgeon's hand and with the surgeon's thumb resting on a slide mechanism 24 . The handle 20 is preferably molded from a suitable medical-grade plastic and formed interiorly therein is a channel through which electrical conductors 26 , 28 and 30 may pass. Affixed to the proximal end of the conductors 26 , 28 and 30 are plugs 32 , 34 and 36 , which are adapted to mate with jacks (not shown) on a standard electrosurgical generator or mode control switch (also not shown).
[0022] Affixed to the distal end 16 of the tubular barrel 12 is an end effector assembly indicated generally by numeral 38 . As can be seen from FIG. 1 and from the enlarged view of the distal end portion of the instrument illustrated in FIGS. 2A and 2B, the end effector comprises first and second hemispherical shaped electrodes 40 and 42 which are disposed in parallel, closely spaced but non-contacting relationship to one another and which are fixedly secured to the distal end 16 of the barrel 12 . The exterior surface of the electrodes comprises conductive metal. The electrodes may be solid metal or may comprise a ceramic substrate on which a conductive metal layer has been deposited. The walls 44 and 46 that define a slot 48 have an insulating layer 50 thereon. Without limitation, the insulating layers 50 may be a ceramic.
[0023] The conductor 26 extends through the handle 20 and through the lumen 18 of the barrel to electrically connect to the electrode 42 . Likewise, the conductor 30 also extends through the handle 20 and through the lumen 18 and connects to the electrode 40 . It should be recognized that the barrel itself can be metal and can serve as a medium for coupling a voltage to one or the other of electrodes 40 and 42 .
[0024] Disposed in the slot 48 is the shank portion 52 of a conductive hook-shaped member electrode 54 . The distal end portion of the shank 52 is bent to form a hook portion 56 as can best be seen in the view of FIG. 1. The conductor forming the hook electrode 54 extends through the lumen of the tubular barrel 12 and partway through the handle 20 where it is coupled to an ear 56 affixed to the thumb slide 24 . Thus, by shifting the thumb slide 24 forward and rearward, the hook portion 56 of the electrode 54 can be made to project from or withdraw into the slot 48 . The insulating layers 50 prevent electrical shorting between the hook electrode 54 and the return electrodes 40 and 42 . The conductor 28 electrically connects to the shank 52 of the hook.
[0025] [0025]FIG. 3 illustrates a switching circuit for controlling the mode of operation of the bipolar electrosurgical hook probe comprising a preferred embodiment of the present invention. The switching circuit of FIG. 3 may be resident in the electrosurgical generator used with the instrument or it may be located within the handle 20 of the instrument. Alternatively, the switching arrangement may be physically located in an adapter box disposed between the instrument leads 26 , 28 and 30 and a conventional electrosurgical generator.
[0026] In the view of FIG. 3, the electrosurgical generator is identified by numeral 58 and it is connected through an on/off switch 60 to a junction point 62 to which the conductor 26 joined to electrode 42 connects. The junction 62 is connected to the pole 64 of a single-pole, double-throw switch having associated with it contacts 68 and 70 . Contact 70 is connected to conductor 30 which leads to the electrode 40 . The RF generator 58 is also connected by a conductor 72 to a pole 74 of a single-pole, single-throw switch having a contact 76 that is coupled by the conductor 28 to the conductive hook 54 .
[0027] The switch 60 may be physically located so as to be operable by the surgeon's foot and, when the mode switches are in the coagulation mode, the RF voltage from the generator 58 is applied between the first and second electrodes 40 and 42 , with the hook electrode 54 being open circuited. When the mode switches are placed in the cut mode, the voltage from the generator 58 will be applied between the electrodes 40 and 42 together and the hook electrode 54 .
[0028] When it is desired to use the hook probe 10 to cut through tissue such as a tubular blood vessel or the like, the surgeon loops the hook 56 about the tubular vessel and, by using the thumb slide, draws it against electrodes 40 and 42 . The surgeon then applies a first voltage, via switch 60 and the mode selection switches S 1 and S 2 between the hook electrode 54 and the return electrode, which, as explained above, during cutting, comprise both the first electrode 40 and the second electrode 42 which are maintained at the same potential. Because of the small surface area of the hook electrode compared to the combined surface area of electrodes 40 and 42 , a high current density is developed proximate the hook to effect cutting through tissue.
[0029] Where it is desired to cut through connective tissue, the hook can be retracted to a point where only the bottom of the hook protrudes out from the slot 48 . By applying a cut voltage to the hook electrode and using the coagulation electrodes as a return, the instrument's end can be swept over the tissue causing it to be transected.
[0030] To effect coagulation, the hook electrode may be retracted fully within the slot 48 and a potential applied by the generator 58 through switch 60 and switches S 1 and S 2 between the first electrode 40 and the second electrode 42 . As the two electrodes are brought into engagement with the bleeding tissue, the RF current produces sufficient heating over the areas defined by the electrodes 40 and 42 to produce coagulation. In that the electrodes 40 and 42 are of generally equal surface area, either one can function as the active electrode while the other serves as the return electrode. The hook can also be used to catch and draw target tissue into contact with the electrodes 40 and 42 to effect coagulation where the hook remains electrically passive. To cut through the coagulated tissue, then, a cut voltage is applied to the hook electrode while the electrodes 40 - 42 act as a common return.
[0031] The coagulation performed by the instrument of the present invention is significantly more satisfactory than what can be achieved when a hook electrode is used as the active electrode and the return electrode comprises a single slotted hemispherical member as in the Fleenor et al. '435 patent.
[0032] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself. | A bipolar electrosurgical hook probe includes an end effector that includes first and second electrodes placed in parallel, closely-spaced relationship, each being of a relatively large surface area and a conductive reciprocally movable hook member that is movable into and out of a space between the first and second electrodes. A switch mechanism is provided by which an RF current can alternatively be made to flow between the first and second electrodes during electrocoagulation and from the hook electrode to each of the first and second electrodes when the instrument is operating in its cut mode. | 0 |
FIELD OF THE INVENTION
This invention relates to augers intended for earth boring, of the kind having hollow stems to facilitate the recovery of samples or the making of tests during boring.
BACKGROUND OF THE INVENTION AND PRIOR ART STATEMENT
When recovering samples using hollow stem augers, the normal procedure has been to remove a closure at the bottom of the hollow stem using a string of rods which are then withdrawn and used to lower a sampling tube or testing tool to the now open bottom of the stem. The tool is then withdrawn again and the closure replaced, again using the string of rods. Particularly with a deep bore, this procedure is extremely laborious and time consuming, and may require to be repeated at quite frequent intervals.
For this reason proposals have been made to provide closure means at the bottom of the stem which can remain in situ during sampling and testing operations. Examples of such proposals are contained in U.S. Pat. No. 3,095,051 issued June 25, 1963 to Robinsky et al, and Canadian Pat. No. 711,139 issued June 8, 1965 to Robinsky. In the first of these patents, the bottom of the auger tube is closed by a valve formed by two spring leaves extending from the bottom of the tube in a cusp-like formation. A sampling tube can be thrust between the valve members formed by these leaves so as to penetrate the soil beneath, and the leaves will spring back into place so as to close the auger stem when the tube is withdrawn. In the second patent, the bottom of the tube is closed by shaped rigid hinged valve members spring urged towards a closed condition. These members also are arranged to be thrust apart by a sampling tube.
With these arrangements it is necessary for the flights of the auger to project forwardly of the spring or valve members, which reduces the support available to the forward portions of the flights and weakens the structure of the auger. Moreover the spring or other valve members are somewhat vulnerable to damage. The valve arrangement increases the cost of the auger, thus providing a substantial financial burden if a range of augers are required to suit different soil conditions, or if frequent repair or replacement is required. It is known to provide earth boring augers with detachable teeth at their leading ends which can be exchanged or replaced as necessary, but these teeth usually require a distribution such that they cannot solely be supported by the leading ends of the flights. In the valved hollow stem augers considered above, the stem of the auger must stop short of the valve and is thus not available to support detachable teeth.
A powerful spring action must be provided by the spring leaves or applied to the valve members to bias them to a closed position, so as to ensure the avoidance of unwanted opening during boring and assured closing when a sampling tube is withdrawn. This power spring action means that considerable force is required to pass a sampling tube or other tool through the closure, and once so passed, it is gripped quite tightly by the spring leaves or valve members. One reason for using a hollow stem auger is to permit tests of the ground being bored by for example determining its resistance to rotation or penetration of test implements, and the gripping action of the spring leaves or other valve members interferes with such tests and prevents the obtaining of meaningful results. The present invention is directed to overcoming these problems.
SUMMARY OF THE INVENTION
In one aspect of the invention, an auger as described in U.S. Pat. No. 3,095,051 or Canadian Pat. No. 711,139 is improved by taking the auger flights at the leading end of a hollow stem auger bit to a ring coaxial with the bit and beyond the outer ends of the spring leaves or other valve members, the ring carrying a plurality of detachable cutting teeth distributed around its periphery. This results in an auger bit in the form of a rigid cage, the valve members being protected by the cage. In another aspect of the invention, the lowermost of a string of rods utilized for raising and lowering and actuating test implements through a hollow stem auger, with a valve at the lower end of the tube spring biased to a normally closed position, carries an external concentric sleeve capable of passage at least partially through the valve and means releasably connecting the sleeve to said rod whereby the latter may be lowered either conjointly with or independently of said sleeve. The string of rods may thus be used to pass the sleeve partially through the valve so as to hold the latter open, whereupon the sleeve may be released from the lowermost rod so that the rods may be used to lower an implement into the soil beneath the auger. Preferably the releasable connection is a key and keyway type coupling which may be released and engaged by simple rotation of the string of rods relative to the sleeve.
Other features of the invention will be apparent from the following description of a preferred embodiment with reference to the accompany drawings.
SHORT DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a vertical sectional view showing an auger in accordance with the invention, in use;
FIGS. 2 and 3 are different side elevations of the auger bit;
FIG. 4 is a section through the auger bit on the line 4-4 in FIG. 2;
FIG. 5 is a view of the lower end of the auger bit;
FIG. 6 is a part elevational, part section view of the lower end of a string of rods used to lower and actuate a testing implement through the auger; and
FIG. 7 is a transverse section on the line 6--6 in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-5, an auger bit 2 has helical flights 4, and is supported by tubular member 6 having external flights 8, the flights serving to lift spoil 10 loosened by teeth 12 up the bore 14 formed by the auger in ground 16 being bored as the bit 2 is rotated. The bit 2 is coupled to the member 6 by a coupling sleeve 18 secured by locking pins so that the bit rotates with sleeve. In order to obtain a core sample of the soil beneath the auger, a sample tube 20 may be passed down the tube formed by the member 6 and the bit 2, driven into the soil and withdrawn so as to extract the desired sample. It will be understood that both the member 6 and the tube 20 may be upwardly extended respectively by as many tubes and rods (not shown) as may be necessitated by the depth of the bore hole.
The bit 2 has an upper ring 22 integral with the coupling 18 and a lower ring 24 spaced below and concentric with the upper ring and the member 6. Two spaced plane parallel side walls 26 connect the rings internally of the flights 4 so as to provide a rigid cage structure with concentric circular openings 28, 30 formed by rings at its upper and lower ends so as to provide sufficient room internally to accommodate flexure of two spring leaves 32 within the cage structure as the tube 20 is thrust between them. The spring leaves 32 are anchored to the upper ring 22 by anchor blocks 34 and screws 36, and their operation is similar to that described in U.S. Pat. No. 3,095,051. The valve formed by the spring leaves 32 could also be replaced if desired by the valve arrangement shown in Canadian Pat. No. 711,139, in which rigid valve members are spring urged to a closed position. As compared to the bit structure of those patents, however, that of the present invention is protected by the cage structure from accidental damage for example by rocks in soil being bored. With the prior art arrangements these could become engaged between the lower ends of the flights and exert considerable forces on the latter, as well as possibly damaging the leaves 32. In the present arrangement, any such engagement with an obstruction large enough to cause damage is prevented by the ring 24, which also braces the flights and supports the teeth 12. The teeth are held in place by screws (not shown) in outward projection from the ring 24 and can readily be exchanged or replaced as required. Their location need not, and in the example shown does not coincide with the ends of the flights, whose sole function becomes the removal of spoil.
As will be readily apparent from FIG. 1, the spring leaves 32 exert a firm grip on the tube 20 when it is inserted between them. This grip is in some instances undesirable, particularly when implements other than coring tubes are employed to carry out tests on the ground being bored. Such tests include vane tests in which an implement with radially extending vanes is rotated in the soil and, the resistance to rotation is measured and penetration tests in which the resistance of the soil to penetration by an implement is measured. Obviously engagement of the leaves 32 with such an implement or its supporting rods will upset the results of the tests being carried out. A manner in which this problem can be overcome is shown in FIGS. 6 and 7.
The test implement shown by way of example in this case is a vane test implement having a shaft 40 and a soil penetrating head formed by radial vanes 42. It is coupled to the bottom of a string of screw-coupled drilling rods 44. The lowermost rod 45 of the string of rods is equipped with at least one and typically two projecting keys 46 secured thereto by screws 48, and may be no more than a short coupling piece as shown. A projecting washer 50 is captive between the shaft 40 and the rod 45 so as to be engageable with a shoulder 52 on a collar 54 which normally surrounds the rod 45 beneath the keys 46. The collar 54 is formed internally with keyways 56 spaced similarly to the keys 46 so that when the rod 45 and the collar are correctly relatively oriented, the keys can pass through the keyways in the collar so as to permit the rods 44 and 45 to move downwardly relative to the collar until the keys leave the lower end of the keyways. The collar 54 supports a sleeve 58 which surrounds the implement and may either be screwed onto the collar as shown, or, if of small wall thickness, anchored thereto by set-screws 60.
In use, the test implement is lowered down the stem of the auger by means of the rods 44 and 45, with the collar 54 resting on the washer 50 so as to support the sleeve 58. When the bottom of the sleeve reaches the spring leaves 32, further lowering of the rods causes the key 46 to engage the top of the collar 54 and thus to force the sleeve between the leaves 32. When the sleeve has moved partly through the valves formed by the leaves so as to hold the latter apart, the rods 44 and 45 are rotated until the keys 46 drop into and through the keyways 56, whereafter the implement may be lowered further and manipulated as desired by means of the rods without interference from the spring leaves 32. When the rods are withdrawn from the auger stem, the shoulder 52 on the collar is engaged by the keys 46 or the washer 50 and the sleeve 58 is also withdrawn.
It will be appreciated that the means used for releasably coupling the sleeve to the string of rods or the test implement could be different from those described. For example remotely controlled means could be provided for withdrawing the keys 46 into the rod 45 to release the collar, but an arrangement using complementary keys and keyways is simple and can be actuated by simple rotation of the string of rods. | In a hollow stem auger for earth boring of the kind having spring loaded valve members at the bottom of the stem to permit the passage of test implements such as corers and vane test implements, the auger bit is constructed with a cage formation enclosing the valve member and supporting a bottom ring carrying cutting teeth. Interference of the valve members with a test implement is prevented by using an uncoupleable cylindrical sleeve surrounding the implement which sleeve can be lodged between the valve members to hold them open during use of the implement. | 4 |
STATEMENT OF GOVERNMENT INTEREST
The invention described and claimed herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of royalties thereon or therefor.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to portable, folding road surfaces primarily employed in military applications.
2. Discussion of the Prior Art
U.S. Pat. No. 4,488,833 to Perry et al. shows the use of hinged multi-hollow sections which may be laid from an accordian position. The individual planks, however, are not pivotable through 360 degrees relative to each other since each plank is folded into its accordian storage position in a single, preset direction of rotation.
Similarly, U.S. Pat. Nos. 4,277,201 to Abell and 3,284,819 to Nissen also show portable roadbeds which lack the 360 degree rotation characteristic.
Finally, U.S. Pat. No. 4,460,291 to Lamendour shows a flexible, portable roadbed wherein a significant degree of rotational flexibility exists between the respective components. However, 360 degree rotation is obviously not possible due to the configuration of the individual members. Further, the top and bottom surfaces of the members are not identical and therefore the roadbed has a specific top and bottom.
SUMMARY OF THE INVENTION
In accordance with the present invention, a folding surfacing module essentially comprises first and second sections, these sections being essentially identical and rectangular in shape with a coupling means connecting the sections which allow each section to move through 360 degrees relative to the other section.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevation view of a surfacing module in accordance with the invention, illustrated in its fully-folded configuration;
FIG. 2 is a partial plan view of the surfacing module illustrating certain details of the hinge assemblies;
FIG. 3 is an exploded isometric view of a typical hinge assembly;
FIG. 4 is a side elevation sectional view of a portion of one of the surfacing module members;
FIG. 5 is a side elevation of a typical hinge link;
FIG. 6 is a side elevation of the hinge area illustrating the relative movement possible between two surface members;
FIG. 7 is a side elevation of the surfacing module in a partial deployment position;
FIG. 8 is an illustration of the surfacing module being deployed; and
FIG. 9 is illustrates the surfacing module fully deployed on a non-uniform surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Road surface units of these types are particularly useful to provide reversible roadways for motor vehicles of varying sizes and weights over uneven and/or unstable terrain. Also, these units are used to provide an access area at the interface between land and bodies of water. Portable roadbed configurations have been tested for the above-recited applications, but none have the features of folding 360 degrees with respect to adjacent panels or either surface being the "top" or "bottom". The extrusions that make up the module are symmetrical, and the module can be placed or retrieved for reuse by beginning at either end and can be driven upon on either side.
This invention provides an expedient method to surface a low bearing strength soil subgrade and distribute the contact loads of wheeled or tracked vehicles. It is useful for surfacing the bank slopes of water obstacles or approaches and exits to military bridge installations. It provides an exit from water obstacles trafficked by military assault swimming and fording vehicles and will withstand both wheeled and tracked vehicle traffic. The surfacing module can be dispensed from its packaging carte down a slope and into the water using an amphibious armored personnel carrier. It can also be dispensed onto a roadway with a previously developed dispenser attached to the rear of a military bridge transport truck. If the soil is too weak to support the truck, the surfacing module may be placed on the truck and dispensed over the rear of the truck such that as the truck moves backward, the surfacing module is deployed under the truck and provides a stable surface for the truck wheels.
A typical module is composed of 25 multi-hollow extruded aluminum panels that are roughly two feet wide by 16 feet long by two inches deep. Ribs roughly one-quarter inch high are located on each side of the panels transverse to vehicle movement to provide traction on the top surface for the wheeled or tracked vehicles and an anchoring system on the bottom surface. Adjacent extruded panels are connected with an aluminum hinge pin and several hinge links. The connected panels were designed to surface an area of roughly 16 feet wide by 55 feet long. This area can be covered through the full deployment of a typical module from a dispenser by three men in approximately five minutes.
The hinge connections allow each panel to be rotated through 360 degrees with respect to either adjacent panel. Thus, the panels can be accordian-folded into a compact bundle. Since the panels can be relatively rotated through a full 360 degrees and they are symmetrical, the module can be accordian-folded from either end as the module has no specific "front" or "back". Likewise, the module has no specific "top" or "bottom" as the ridges and other features of the module are symmetrical about the horizontal centerline of the deployed module.
The surfacing module of the present invention comprises a series of hinged sections which together form a road surface which is portable and foldable. FIG. 1 shows the surfacing module in its folded position. In this position, the surfacing module occupies a minimum of volume and is readily bundled, through the use of straps, for transport to a desired location. Identical sections 10 are stacked side-by-side; this arrangement is made possible by the parallel, annularly apertured joining members 4 which link the ends of each section 10. Not only do the joining members allow for adjacent sections to be folded side-by-side, but also the joining members by creating a double, parallel hinge configuration, allow rotation of the sections through 360 degrees relative to adjacent sections.
FIG. 2 illustrates the manner in which a series of joining members 4 are used to link each section 10 with its adjacent section 10. Typically, sixteen of such joining members 4 would be used in a single connection between two sections. Two hinge pins 2 are used at each section connection. One hinge pin passes through the annular apertures 16 of one section and one of the annular apertures of the joining members while the other hinge pin similarly passes through the adjacent section and intervening joining members. Threaded ends 8 secure the hinge pins in place. This unique arrangement is responsible for the 360 degree flexibility that each section enjoys with respect to its adjacent sections.
As can be seen from FIG. 2, the sections and joining members are configured such that when the sections are connected the clearances between the adjacent sections 10, and also between each section and the joining members 4, is relatively small. This is of special significance when the surfacing module is used over wet or muddy terrain since there is a tendency for the loose, semi-liquid material below to ooze up onto the roadway surface or be squeezed up onto the roadway surface through its continued use by vehicular traffic. Additionally, it should be noted that the hinge pins 2 are continuously and completely enclosed by the joining members 4 and attached shaped section connectors 18. This prevents exposure of the hinge pin 2 to the outside elements as well as help prevent the entrance of dirt and other particles into the bearing surfaces.
FIG. 3 more clearly illustrates the joining arrangement between the sections. A washer 9 may be used on the hinge pin 2 as shown in FIG. 3 in order to help alleviate wear and friction between the threaded cap 8 and the connector 18.
The structural details of the section 10 and joining member 4 are shown in FIGS. 4 and 5. In FIG. 4, the hollow cellular structure of the section is illustrated by the various cellular divisions 14, 14' and 14". Transverse ridges 12 appear on either side of the section 10 and are in vertical alignment with section walls 13; see also FIG. 3. These ridges serve a dual function of both anchoring the servicing module to the terrain surface and aiding vehicle traction. FIG. 4 also shows the symmetrical design of the typical section which allows for its above-mentioned surface reversibility.
Both ends of every section have annularly apertured connectors 18 attached thereto, as shown in FIGS. 3 and 4. These connectors have annular apertures 16 for receiving the hinge pins 2. The connectors 18 are aligned such that the joining members 4 may be slid in between them and are also aligned with hinge pin 2. FIG. 4 shows a lobe 17 on the end of the connector 18. This lobe is particularly useful in the folding and unfolding of the invention. As shown in FIG. 7, the sections 10 are slid along the terrain surface on their lobed ends. The lobes serve not only to aid in the sliding of the members over the terrain by reducing the surface area contact of the invention with the ground surface, but also help prevent wear and damage to the joining members by elevating them somewhat off the terrain. This elevation also helps prevent the introduction of dirt and other foreign matter into the hinge itself.
In FIG. 5 the structure of the connecting member is outlined. A hollow cell 5 is provided between the joining member annular apertures 6. This hollow cell 5, much like the hollow cells 14, 14' and 14" of section 10, are present primarily to reduce the weight of the surfacing module.
FIG. 6 again illustrates the relative degree of movement possible between two adjacent sections and their intervening joining member. It should be noted that FIG. 6 only illustrates a typical relative position between the three hinged elements and does not show the full degree of movement possible among them. The position illustrated, however, might well be a position assumed by the surfacing module when installed on a portion of rough terrain as is generally shown in FIG. 9. The hinged arrangement will also allow one section to be displaced upon the application of force, for example from an overpassing vehicle, without necessarily disturbing or displacing adjacent sections. This allows the surfacing module to conform very closely to the surface upon which it is laid (FIG. 9) yet still provide a readily passable surface. This is desirable in that the area under the roadway that is supported by the ground surface is increased, thereby helping to eliminate any unsupported areas that would have to be bridged by the roadway. Bridging, of course, would involve the application of high bending moments and shear loads to the roadway. Further, the unique design minimizes the transmission of vibrations, displacements and forces among adjacent sections of the roadway.
FIGS. 7 and 8 illustrate two means by which the surfacing module may be deployed. The surfacing module may be set out manually from its position on the ground as shown in FIG. 7. Typically, this may be accomplished by one or more men pulling on an end section whereby the surfacing module then slides into place as illustrated, for example, in FIG. 9. Alternatively, the surfacing module may be deployed from the back of a truck, as shown in FIG. 8. In this particular illustration, the surfacing module is being laid out by backing up the truck over the laid out portion of the surfacing module. This deploying scheme is particularly useful when the terrain to be covered is unsuitable for any type of vehicular traffic. The module is also well suited to many other deployment schemes, including being laid from the back of a truck which is moving in the forward direction.
While the invention has been disclosed herein by reference to the details of preferred embodiments, it is to be understood that this disclosure is intended in an illustrative rather than in a limiting sense, as it is contemplated that modifications will readily occur to those skilled in the art, within the spirit of the invention and the scope of the appended claims. | A portable, foldable surfacing module is disclosed for use by road vehicles as a road surface over previously impassable terrain. The surfacing module employs hinged sections that are rotatable through 360 degrees relative to each other and are foldable upon each other in accordian fashion for convenient storage, transport, deployment and retrieval. | 4 |
BACKGROUND OF THE INVENTION
Exercising of the different body limbs and other parts of the body have, in recent years, enjoyed a surge in popularity which has resulted in a plethora of exercise machines to accomplish exercises for different areas of the body. For example, many exercise machines are known which exercise primarily the arms such as the exercise machines shown in U.S. Pat. No. 4,316,609 to Silberman, and for leg exercises as shown in the patent of Pridgen, U.S. Pat. No. 3,834,496. Various other patents, such as U.S. Pat. to Lloyd, No. 3,664,666; Dudley, No. 4,344,618; and Ceppo, No. 4,252,314, show various exercise devices for combination exercises where both exercising of the arms and the legs may be accomplished. However, no devices presently exist for accomplishing sit-up exercises where the exerciser is working against a restraint other than body weight or body position in doing the exercise. The patents above to Lloyd and Silberman, however show sit-up benches for accomplishing sit-up exercises without the use of a restraint or other means whereby weight is added to the shoulders to effect an increased effort to do the exercise. In exercising through sit-up exercises, it is possible to strengthen the lower back muscles through continued practice.
It is to the desire of the Inventor to provide a device whereby sit-up exercises may be accomplished and to which variable restraints may be applied to enable the exerciser to build up the body muscles which are utilized when doing the exercises.
SUMMARY OF THE INVENTION
The subject invention is a device whereby an exerciser may accomplish sit-up exercises while at the same time applying restraint to the exerciser's shoulders to increase the effort which the exerciser must expend in performing the exercise over that without the restraint. By such means, the muscles which are utilized by the body in accomplishing the exercises may be strengthened.
To this end, the preferred embodiment of the invention employs a horizontal bench for the exerciser to recline on, with the front end of the bench on which the exerciser would place his back hinged in order that it may be set at a desirable angle. Located at the front portion of the bench proximate the slanted raised front end are a pair of shoulder harnesses, the harnesses in turn attached by a rope which encircles a pulley near the front end of the bench, the rope next directed to one or more tension springs, the other end of the tension springs anchored to the bench frame. By such placement of the pulley from which the rope emerges, the restraining force applied to the exerciser's shoulders is applied at an angle approximated perpendicular to the plane of the exerciser's back. Suitable adjustment of the location of tension springs and/or length of the rope allows the exerciser to engage the restraining force at any time in the sit-up exercise, either initially from the reclining position or any point in the pivotal movement of the exerciser's back as it rotates at the waist. The opposing spring tension restraint may be varied by choice of interchangable springs, or by the addition of a plurality of tension springs. The sit-up bench is characterized by a horizontal foot hold down bar spaced above the rear end of the sit-up bench surface to provide means to keep the exerciser's legs from rising as he performs the sit-up exercises.
In an alternate embodiment fo the invention, additional features for leg exercises are added at the rear portion of the bench where, utilizing the same spring tension mechanism as was used in the sit-up exercises, a pivoting bar with cross members at each end adapted to engage the sitting exerciser's legs in a down-vertical configuration in one position, or, the exerciser's legs in a straight-out configuration in a second position while the exerciser is on his stomach. With the exerciser's legs in a down configuration, the cross member attached to the pivotal bar is raised against the spring tension restraint by the exerciser rotating his legs outward and upward. In the second position, the pivotal bar may be pivoted frontwards against spring tension by the exerciser, laying on his stomach on the bench, by bringing his legs from a substantially horizontal position to a back-folded position.
It is an object of the subject invention to provide a device by which an exerciser may accomplish sit-up exercises while working against a restraining weight or force.
It is further an object of the subject invention to provide a combined exercise bench for performing sit-up exercises against a restraining force, and to provide leg exercises for the legs also to work against a restraining force.
Other objects of the invention will in part be obvious and will in part appear hereinafter. The invention accordingly comprises the apparatus possessing the construction, combination of elements, and arrangement of parts which are exemplified in the following detailed disclosure, and the scope of the Application which will be indicated in the Claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For further understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings wherein:
FIG. 1 is a side elevational view of the inventive sit-up exercise bench;
FIG. 2 is a rear elevational view of the inventive sit-up exercise bench;
FIG. 3 is a top view of the inventive sit-up exercise bench; and
FIG. 4 is a perspective view of an alternate embodiment of the inventive sit-up exercise bench with additional leg exercise attachments.
In the various views, like index numbers refer to like elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a side elevational view of the inventive sit-up exercise bench 10 is shown.
Proceeding from the ground level, the exercise bench has two rear legs 12 and two front legs 14. Both pair of legs are braced to the center support frame 16 by angle braces. All legs have a rubber foot attached at their end for placement on the floor.
Center support frame 16, nominally 6 feet long or so, is designed to support the weight of an exerciser sitting on seat cushion 18 generally mid-way between the legs. Immediately to the front of seat cushion 18 is hinged back cushion 20 which provides an adjustable angle backrest for the exerciser. The hinged back cushion 20 hinge 22 is attached to center support frame 16 at at least two positions. The angle of hinged back cushion 20 may be adjusted by placement of back adjustable rod 22 which spans the distance between the two front legs 14 and resides in one of the plurality of openings 24 which appear in each of the two front legs 14. Shown in FIG. 1 is the wing nut 26 which screws on to each of the threaded ends of the back adjustable rod 22, the circular end of such rod being the only part visible in FIG. 1.
At the rear portion of center support frame 16 is rear leg cushion 28 which lies atop the center support frame 16. Immediately above the rear portion of rear leg cushion is the tubular foot hold down bar 30. Foot hold down bar 30 is preferably covered with vinyl plastic over interior padding, as are the cushions 28, 18 and 20.
Running parallel to the longitudinal side of center support frame 16 is adjustable spring holding mechanism 32 comprising a short piece of 3/4 square iron plate with a hook attached on one side. Through two sides of the iron plate is a hole through which a bolt is pushed to engage a corresponding hole in center support frame 16 and then through a hole on the opposite side of the iron plate. Shown in FIG. 1 is adjustable spring holding mechanism 32 in place with a wing nut screwed on to the end of the bolt which holds the iron plate in place. The mechanism may be adjusted to the rear from the position shown by removal of the bolt, the mechanism moved and relocated to the new position, and the bolt replaced.
Attached to adjustable spring holding mechanism 32 by means of an outstanding hook is one end of tension spring 34, the other end of spring 34 attached to rope 36. Rope 36 travels longitudinally along the side of the center support frame 16 until it reaches pulley 38 wherein the rope 36 engages and wraps partially around pulley 38 and then travels upward to attach to harness 40 which the exerciser places around his shoulder.
In practice, the person performing the sit-up exercise sits on seat cushion 18, reclines his back on hinged back cushion 20, and then places his feet on rear leg cushion 28. Foot hold down bar 30 would normally reside in a position about 6 inches above real leg cushion 28 which would be approximately 1 inch above the exerciser's legs, serving to provide support to prevent the legs from rising higher as the exerciser works out. The exerciser, now laying with his back in an inclined position, will place harness 40 around one shoulder, and then proceed to pivot upright at the waist against the restraining force applied by tension spring 34 through rope 36. It is anticipated that the sit-up restraining means comprising the mechanism 32, tension spring 34, rope 36, pulley 38, and harness 40 is duplicated on the opposite side of center support frame 16 so that the sit-up exerciser may work with one restraining means, or both restraining means simultaneously.
In utilizing the machine, the exerciser will do multiple sit-up movements, both rising and then returning to the original position. Obviously, by adjustment of rope 36, resisting tension can be applied at any point in the exercise, either from the beginning, or only to come in when the exerciser's back has reached a certain position. It is noted that by the placement of pulley 38, rope 36 attached to harness 40 places the restraining means on the exerciser's shoulder at an angle that is approximately 90° to the plane of the exerciser's back.
To allow the exerciser different initial inclined positions, selective placement of the back adjustable rod 22 in different openings 24, which openings are located across from each other on both front legs 14, are permitted.
Shown in dotted form for the use of the sit-up exercise bench 10 is an alternate, but well known exercise of lifting weights from a position of one being flat on their back. To accomplish this exercise, hinged back cushion 20 is lowered to a horizontal position, shown in dotted form, and then use is made of lifting weights (also shown in dotted form), whose center bar resides in stirrup 42. Stirrup 42 is attached to adjustable rod 44, which in turn slidably resides interiorly to front legs 14. A hole is drilled near the top of front leg 14 and pin 46 penetrates the hole to engage one of a plurality of like holes in adjustable rod 44 in order that the position of stirrup 42 may be adjusted to adjust the height of the weights above the bench.
With the additional exercising means above described, the exerciser can lower the hinged back cushion 20 to a flat position and, by lying prone on his back on sit-up exercise bench 10, can lift weights with his arms.
Referring now to FIG. 2, an end elevational view of the sit-up exercise bench 10 is shown. Immediately visible, starting from the lower portion of the Figure, are the pair of rear legs 12, with the floor rubber feet attached, and the end of center support frame 16 which attaches to the top of the rear legs. Rising above the end of center support frame 16 is the foot hold down bar 30, rising upon a fixed support 31 centrally attached to center support frame 16. Shown centrally to foot hold down bar 30, in dotted form, is the surrounded central bar about which the padding and vinyl plastic cover is wrapped. Located between front legs 14, the bottom-most portion of which is hidden below the center support frame 16 and cushion 28, is hinged back cushion 20. Holding hinged back cushion 20 in its slanted upright position is the back adjustable rod 22 (not shown), such rod having connected at both ends the wing nuts 26. Rising above the tops of front legs 14 are the pair of interiorly adjustable rods 44 which in turn are connected to stirrups 42. Residing within the concave portion of stirrups 42 is the weight center bar 46, with annular weights 48 on each end.
Additionally, shown in FIG. 2 is the end view of the adjustable hooks 32 and tension spring 34. Not visible are the attaching ropes 36 attached to their respective harnesses 40.
Referring now to FIG. 3, a top view of the subject inventive sit-up exercise bench 10 with the seat cushion 18 and rear leg cushion 28 situated upon frame 16. Commencing at the rear portion, the outline (dotted) of the center support frame 16 is shown with the two side bars and the end piece. Attached to the end piece is fixed support 31 (shown in dotted form) which attaches to foot hold down bar 30. Proceeding upward on center support frame 16, the adjustable spring holding mechanism 32 is shown comprising the 3/4th. square iron plate with opposite holes which receive the holding bolt and its wing nut for adjustable placement along the side pieces of center support frame 16. To this adjustable spring holding mechanism 32 is connected tension springs 34 (one on each side), which in turn is connected with rope 36. The ropes extend along each side of center support frame 16 where they engage pulleys 38 before turning upward. Ropes 36 are terminated in FIG. 3 prior to attachment to their respective harnesses 40 (not shown).
Further shown in top view of sit-up exercise bench 10 in FIG. 3 is at the terminus of center support frame 16 the front legs 14 with concentrically located adjustable rods 44 (not shown), which in turn are attached to stirrups 42. Crossing transversely the hinged back cushion 20 is the annular weights 48 central bar 46.
In utilizing the invention shown and described in FIGS. 1-3, the exerciser may adjust the relative position of the harnesses 40 if rope 36 is of a fixed length by adjustment of the relative position of spring 34 by adjustment of the adjustable spring holding mechanism 32. Also, as previously indicated, the initial starting position of the exerciser's back is adjustable by adjustment of the hinged back cushion 20 through selective placement of the back adjustable rod 22 (shown dotted in FIG. 3).
Referring now to FIG. 4, a perspective view of an alternate embodiment of the invention coupled with a leg exerciser is detailed. More specifically, center support frame 16 and its top cushions, hinged back cushion 20, seat cushion 18, and an expanded rear leg cushion 68 provides means for the exerciser to lay fully prone on the bench for the expanded exercises. Added to the bench at the rear end portion thereof is the leg exercise mechanism 50 comprising an arcuate shaped bar 52 with upper transverse bar end 54 and lower transverse bar end 56, each attached at a 90° angle to the arcuate-shaped bar 52 at the upper and lower ends respectively. Arcuate-shaped bar 52 is pivotally attached in its center area to the end portion of frame 16 by means of a pivot mechanism. The pivot mechanism shown in FIG. 4 comprises a pair of parallel metal bars 58 with a pin at each end connecting the bars, one of such pins passing through an opening crosswise in arcuate-shaped bar 52, and the other pin passing through a hole in a rectangular shaped metal sleeve 59 attached to the end of frame 16. It is noted that the rectangular shaped sleeve 59 attached to the end of frame 16 has a plurality of holes passing through it in order that the parallel bars on each side of sleeve 59 may be located at variable positions. By such choice of placement, the height of the pivoting point of arcuate shaped bar 52 may be raised or lowered for the convenience of the exerciser.
It is additionally noted that one of the two spring tension mechanisms 64 (the other spring tension mechanism located on the opposite side of frame 16 and not shown) is detailed. In this FIG. 4, spring mechanism 64 comprises a pair of rectangular plates with a plurality of hooks on one side by which one or more tension springs may be connected. The rope 36 which passes over pulley 38 to harness 40 attaches at the corner of one of the triangles opposite the spring hooks, and that a hole is located somewhat central to the triangle piece. The purpose of the central hole is to permit a bolt to engage and hold the triangle piece to frame 16, or, as shown in FIG. 4, to the added frame support 17 passing between the front and the rear legs. In the illustration shown in FIG. 4, the lower portion of arcuate-shaped bar 52 is attached to the spring tension mechanism 64 by means of an eye bolt whose shank passes through arcuate-shaped bar 52, and rope 62 which attaches the eye of the eye bolt to the right hand side triangle piece of spring tension mechanism 64. In the particular situation shown in FIG. 4, the left handed triangle pice of spring tension mechanism 64 will be held stationary by the bolt attaching both frame support 17 and the triangle piece.
Additionally, at the rear end portion of the sit-up bench shown in FIG. 4, foot hold down bar 60 is shown placed in its lowest most position, next to expanded rear leg cushion 68. The vertical bar attached to foot hold down bar 60 slides interiorly to sleeve 59 which allows height adjustment for the pivoting mechanism 58. The same pin of the pivot mechanism parallel bars 58 used to adjust the pivotal position of arcuate shaped bar 52 is used to adjust foot hold down bar 60. Obviously the vertical bar attached to foot hold down bar 60 is penetrated by a plurality of holes.
In using the leg exercise embodiment of FIG. 4, the exerciser first needs to secure spring tension mechanism 64 by loosening the right hand triangle piece from frame support 17 by removal of the bolt engaging the hole in the triangular piece and then secure the left hand triangle piece of spring tension mechanism 64 to frame support 17 in order that the arcuate-shaped bar 52 may pull on the spring through rope 62. To exercise using the lower transverse bar 56, the exerciser sits on the rear end portion of the sit-up bench with the arcuate-shaped bar 52 between his legs, placing lower transverse bar 56 on the front part of his foot, preferably near the point where the foot joins the leg. Then, by raising his legs up, pivoting outward, the exerciser pivots arcuate-shaped bar 52 about its pivot mechanism, lower transverse bar 56 then swinging in an arc upwards.
The travel of lower transverse bar 56 is opposed by spring tension mechanisn 64 so that exerciser will have resistance to the movement of his legs, and thus will gain the exercise desired. The amount of spring tension which resists the exerciser's leg movement may be varied by placement of different tensioned springs between the two end triangular pieces of spring tension mechanism 64 or, multiple springs may be employed in spring tension mechanism 64 to increase the tension. Conversely, fewer springs or weaker springs, will lessen the spring reistance.
To accomplish the leg exercises utilizing upper transverse bar 54, the exerciser lies flat on the sit-up bench, stomach down, with the exerciser's knees near the rear end portion of expanded rear leg cushion 68. Then, the exerciser places his legs on either side of the arcuate-shaped bar 52 with the portion of his body between the ankle and the leg just under and thereby engaging, upper transverse bar 54. Then, the exerciser will, while laying on his stomach, bring his lower leg towards him, such as to close the angle made by the upper and lower portion of the legs, and in doing so, rotates arcuate-shaped bar 52 and upper transverse bar 54 will swing in an arc towards the front portion of the sit-up bench. Again, movement of the arcuate-shaped bar about its pivotal mechanism will be opposed by the spring tension mechanism 64, the operation of this mechanism similarily as explained above.
It is noted in the alternate embodiment shown in FIG. 4, that some additional changes have been made to the construction of the sit-up bench over that shown in the FIGS. 1-3. For example, the mechanisms holding the weights overhead for use by the exerciser has been moved a short distance towards the center of the sit-up bench, and that the spring mechanism attaches to frame support 17 residing slightly lower than the center support frame 16. Further, it is anticipated that two spring tension mechanisms such as shown by member 64 will be utilized in the alternate embodiment, one such mechanism on each side of the bench. A portion of the rope connecting arcuate-shaped bar 52 to the second spring tension mechanism is shown in FIG. 4.
While a preferred and alternate embodiment of Applicant's invention has been shown and described, it is appreciated that still other embodiments of the invention are possible and that there is no intent to limit the invention by such disclosure, but rather it is intended to cover all modifications and alternate embodiments falling within the spirit and the scope of the invention as defined by the appended claims. | A sit-up exercise bench comprising a horizontal platform connected to a slant-adjustable back rest, a harness adapted to be engaged by an exerciser's shoulder, said harness operably connected to a restraining spring attached to said horizontal frame whereby an exerciser, reclining upon the bench, may perform sit-up exercises from the waist, sitting up against the resistance provided by the tension springs. In an alternate embodiment, a pivotable arcuate-shaped bar attached to tension springs for engagement by the exerciser's legs provide restraining force to movement of the exerciser's legs in two positions. | 0 |
FIELD OF THE INVENTION GROUP
This invention relates generally to safes and currency storage devices, and more particularly to portable currency holders accessible by a unique device quite unlike a common key.
BACKGROUND OF THE INVENTION
The rise in popularity of casinos in the United States has highlighted that many recreational gamblers lack the discipline to retain a portion of their winnings while they continue to gamble. Since the long term odds favor the house, it is a fundamental rule of gambling that at least a portion of any winnings be retained and not be put at risk on subsequent wagers. But modern casinos are designed to maintain an atmosphere of gambling excitement, testing the resolve of most recreational gamblers and causing them to continue to risk their winnings, to the casino's long term advantage.
The present invention is directed toward a solution for that lack of discipline. Although currency storage devices for securing paper currency and the like against immediate access by its user are known, there is a need for a device portable enough to be carried discretely in a gambler's pocket, and that is accessible only by a special key, which ideally the gambler leaves at home or at least in a remote location. This disclosure allows a gambler to put a portion of his winnings (converted into currency) into a box where his jackpot is inaccessible. If he should encounter a subsequent losing streak he will be unable to access the winnings secured in the storage device until he returns home.
While the casino application is the most obvious one, the present invention is useful for securing paper currency and the like from others, as well as from the user. Travelers may use it while away from home to hide their cash from hotel chambermaids unaware of the contents of the device. Purse snatchers may discard it with a purloined purse for the same reason, giving the victim a chance at recovering her cash if the purse is found.
SUMMARY OF THE INVENTION
In accordance with the present invention, a portable device for holding paper currency is provided, comprising a base and a cover being moveable relative to one other and defining an interior compartment, a locking mechanism to prevent movement of said base relative to said cover, and escapement means for receiving paper currency and the like into said interior compartment. Separate from the currency holding device but necessary to non-destructively access its contents is a multi-faceted key comprising a body and projections therefrom adapted to disengage said locking mechanism of said currency storage device by depressing retractable pins of said locking mechanism, thus allowing said base and cover to move relative to each other and expose said interior compartment.
In the preferred embodiment described in detail below, the locking mechanism comprises retractable pins in the cover or base, and complementary holes in the other of said cover or base that receive the retractable pins when the cover and base are slideably engaged. The escapement means is a manual thumbwheel and an inlet ramp, each partially extending into a slot, said slot being in communication with both said interior compartment and the exterior of the device.
The thumbwheel and the inlet ramp act in concert to facilitate putting paper currency into the interior compartment through the slot but inhibiting its removal therethrough. The multi-faceted key of the preferred embodiment comprises a body equipped with fixed pins extending therefrom and so positioned as to be received through the holes of the cover to simultaneously urge the retractable pins of the base toward a retracted position, allowing the base and the cover to be slideably disengaged.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention and many of its attendant advantages will be readily appreciated and better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of the preferred embodiment of the portable currency storage device.
FIG. 2 is an exploded view of the cover and base of FIG. 1 .
FIG. 3 is a perspective view of the cover of FIG. 1 showing its interior.
FIG. 4 is a perspective view of a key used to access the preferred embodiment of the portable currency storage device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention, depicted in perspective view at FIG. 1 and designated generally as 20 , comprises a cover 22 having a cover top surface 24 , a cover front surface 26 , and projecting tabs 28 . A base 30 similarly has a base bottom surface 32 , a base front surface 34 , and projecting tabs 36 . The cover and base projecting tabs, 28 and 36 respectively, are complementary to each other, and interlock to enable the cover 24 and the base 30 to slideably engage each other. When so engaged, the cover and base define an interior compartment shown particularly in FIG. 2 and described below. The interior compartment is designed to accommodate folded currency so that the currency storage device may be discretely carried in a pocket.
The cover 22 and the base 30 define a slot 38 in communication with the interior compartment and the exterior of the currency storage device. Projecting partially through the cover top surface 24 is a thumbwheel 40 for drawing and assisting paper currency into an interior compartment of the portable currency storage device. The cover also defines holes 42 extending therethrough for a purpose to be described below.
FIG. 2 shows an exploded view of the cover 22 and base 30 , wherein the interior compartment, shown generally at 44 , is defined by the base top surface 46 , the sidewalls 48 , and the cover bottom surface 50 . Along the tops of the sidewalls are a plurality of retractable pins 52 that are biased to the extended position (as shown), said retractable pins being aligned with the holes 42 when said cover 22 and said base 30 are slideably engaged. When the cover 22 and the base 30 are fully engaged so that the front surfaces 26 and 34 are flush, the bias of the retractable pins 52 causes them to extend into the holes 42 , thus preventing the cover 22 and the base 30 from being slideably disengaged except when said pins 52 are retracted. This retraction is done by a key 54 , described below and shown in FIG. 4 .
The cover 22 is shown in isolation at FIG. 3, in a position inverted from that of FIGS. 1 and 2 to particularly expose the interior of said cover 22 . The interior compartment is shown generally at 44 . The thumbwheel 40 projects partially into the slot 38 . Between the thumbwheel 40 and the interior compartment 44 is an inlet ramp 56 having an inclined segment 58 adjacent to said thumbwheel 40 . Paper currency fed through the slot 38 passes over the thumbwheel 40 and over the inlet ramp 56 towards the interior compartment 44 . The inlet ramp 56 progressively restricts the size of the slot 38 so that paper currency may pass with relative ease toward the interior compartment. However, once inside the interior compartment 44 , folded currency will tend to expand, and the absence of an inclined segment adjacent to the interior compartment 44 serves to prevent said currency from passing out of the interior compartment 44 through the slot 38 .
A key 54 is provided as in FIG. 4, comprising a body 60 and a series of fixed pins 62 projecting therefrom. Operation of the key 54 is best understood with reference to FIGS. 2 and 4 together, recognizing that FIG. 4 is oriented to expose the operable surface and must be mentally inverted to properly align with the depiction of FIG. 2 . The fixed pins 62 are oriented to simultaneously project into each of the holes 42 of the cover 22 when the body 60 is place flush against the cover top surface 24 . Assuming the holes 42 have a depth d, the fixed pins 62 project from the body 60 a similar length d, such that when the key 54 is placed against the cover top surface 24 , each fixed pin 62 depresses one retractable pin 52 . Since the depth of the holes 42 substantially equals the length that the fixed pins 62 extend from the body 60 , the retractable pins 52 are retracted enough to allow the cover 22 and base 30 to be slideably disengaged.
FIG. 4 shows an optional raised lip 64 on three sides of the body 60 . This raised lip 64 serves dual purposes. First, it aids in aligning the fixed pins 62 of the key 54 with the holes 42 of the cover 22 , by partially enveloping three sides of the cover 22 . Second, it protects the fixed pins 62 from being inadvertently bent, because the raised lip 64 extends slightly higher than the length d of the fixed pins 62 .
The preferred embodiment described above employs an aluminum cover, base, and key, with steel retractable pins. The above embodiment is illustrative rather than exhaustive. Various substitutions of components described herein will be obvious to skilled artisans in light of the above teaching, such as employing high impact plastic for several component parts, substituting an alternative locking mechanism for the retractable pin/hole arrangement, or employing a battery driven thumbwheel that may or may or penetrate the cover top surface. The preferred embodiment employs cylindrical shaped projections as the pins, but the term ‘pins’ as used herein includes projections having various cross sections (i.e. square, rectangular, ocatagonal, etc.). The scope of the following claims encompass such modifications and variations in accordance with the doctrine of equivalents. | A portable currency storage device for securing paper currency and the like against immediate access includes a cover and base slideably joined and locked together. A thumbwheel is provided to assist paper currency and the like into an internal compartment of the device, but is unable to withdraw the same. The internal compartment and its contents are accessible only by separating the cover from the base using the key provided for such. | 4 |
BACKGROUND
The invention relates to a multimode interference coupler (MMI) having at least one supply waveguide and at least one output waveguide.
MMIs of the type mentioned at the outset comprise a waveguide in which a plurality of optical modes can be excited. At least one supply waveguide, usually a single-mode supply waveguide, supplies this waveguide with optical signals which excite the modes which are able to propagate in the MMI. If a plurality of the modes which are able to propagate are excited, they come to interfere inside the MMI. At least one maximum of the interference pattern is injected into an output waveguide, usually a single-mode output waveguide.
MMIs are used, in particular, in optical data transmission networks to divide optical signals from one supply waveguide, for example, among two or more output waveguides. For this purpose, the geometry and refractive index of the MMI are configured in such a manner that the desired field strength and phase angle of the output signals produced are achieved.
SUMMARY
The invention is based on the object of specifying a multimode interference coupler and a method for the structural configuration thereof, which has an improved uniform distribution of the outgoing signals. Another object of the invention is to specify a multimode interference coupler which has lower losses. Another object of the invention is to control the intensity distribution and the phase distribution of the modes which are able to propagate in an MMI in such a manner that low losses and a uniform intensity distribution are established in all output waveguides even in the case of MMIs having a multiplicity of outputs.
According to the invention, the objects are achieved by a multimode interference coupler (MMI) having at least one supply waveguide and at least one output waveguide, the multimode interference coupler having, along its longitudinal extent in the direction of the supply waveguide, at least one longitudinal section in which the refractive index has a locally oscillating profile in a direction running substantially at right angles to the direction of the supply waveguide.
The object is also achieved by a method for the structural configuration of a multimode interference coupler, in which the profile of the refractive index n(x) is determined, on the basis of the spatial coordinate x along the width of the multimode interference coupler, by the following equation:
n 2 ( x ) = n 0 2 ( x ) + ∑ k = 0 M - 1 N k · φ k ( x ) ,
where n 0 (x) denotes the refractive index of a known multimode interference coupler that is constant in sections, M is the number of modes which are able to propagate in the multimode interference coupler, N k are numerical coefficients and φ k (x) denotes a set of basic functions.
The invention recognized that, in the previously known MMIs, higher-order modes experience a lower effective refractive index than that required for an ideal behavior of the MMI. Therefore, the invention proposes modifying the refractive index of the MMI in a spatially dependent manner in such a way that higher-order modes experience a higher effective refractive index without disturbing the propagation of lower-order modes. In the sense of the present invention, an effective refractive index is understood in this case as meaning an average value of the refractive index experienced by the relevant modes along their propagation path.
It was also recognized that the refractive index profile proposed above can be achieved using small signal approximation in which interference is added to the refractive index of a known MMI that is constant in sections.
In this case, the interference is modeled by a sum of basic functions which may include, for example, trigonometric functions, rectangular functions, triangular functions, sawtooth functions or the like. In this case, each basic function is weighted with a numerical coefficient. The magnitude of this numerical coefficient depends on the selected basic functions and can be determined in an optimization method known per se.
In some embodiments of the invention, optimization is carried out in this case in such a manner that a desired target profile of the optical intensity is compared with the calculated profile and the parameters N k are adapted until the discrepancies have undershot a predefinable limit. The refractive index profile obtained in this manner is substantially independent of the choice of basic functions. However, the latter influence the convergence behavior of the calculation of the coefficients N k and the representation of the refractive index profile.
The refractive index profile calculated using the method proposed according to the invention usually has an oscillating or meandering profile in the region of the multimode waveguide. In this case, the distance between adjacent maxima or minima is usually between 50 nm and 400 nm. In this case, the distance between adjacent minima or adjacent maxima depends, in particular, on the geometrical dimensions of the MMI, the wavelength of the radiated light and the desired interference image.
It has also been shown that the interference image is favorably influenced if the profile of the refractive index does not form any sharp edges at the edges of the MMI toward the surrounding material but rather the refractive index gradually falls to the value of the surrounding material. The refractive index profile obtained using the method proposed according to the invention cannot usually be represented by a closed analytical function.
It has been shown that an effective refractive index, which, for the modes which are able to propagate, decreases in a substantially quadratic manner with the number of modes, is produced inside the MMI by using the proposed method for producing a refractive index profile of an MMI. In this case, in some embodiments of the invention, the effective refractive index n eff of a real MMI may differ from the calculated behavior on account of manufacturing tolerances. Nevertheless, the effective refractive index n eff for the modes which are able to propagate always exhibits better approximation to the ideal quadratic behavior than when using a known refractive index profile which is constant in sections.
The refractive index profile according to the invention reduces the losses produced between the radiated optical power and the optical power coupled out of the MMI. In this case, an ideal MMI may also have losses; in the sense of the present invention, only those losses which additionally occur in the MMI on account of the non-ideal field distribution are therefore referred to as losses.
In one refinement of the invention, the basic functions φ k (x) describe the field distribution of the excitable modes in the multimode interference coupler with the refractive index n 0 (x). It has been found that it is possible to determine the numerical coefficients n k for these basic functions in a particularly simple manner.
In some refinements of invention, the basic functions of only a sub-selection of modes which are able to propagate, rather than of all the modes which are able to propagate, are taken into account when optimizing the refractive index profile. This sub-selection may include, for example, those modes which are excited more strongly than a predefinable limit value by the respective signal from the supply waveguide. This both accelerates the convergence of the calculation and improves the quality of the index profile n(x) obtained.
The invention shall be explained in more detail below using exemplary embodiments and figures without restricting the general concept of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the diagrammatic structure of a known multimode interference coupler using the example of a 1×1 MMI.
FIG. 2 shows the profile of the refractive index of a known 1×1 MMI and of a 1×1 MMI according to the present invention.
FIG. 3 shows the effective refractive index of the known 1×1 MMI and of the 1×1 MMI according to the present invention on the basis of the number of modes.
FIG. 4 shows the lateral profile of the field strength in the output plane of a known 1×1 MMI.
FIG. 5 shows the lateral profile of the field strength in the output plane of a 1×1 MMI according to one exemplary embodiment of the present invention.
FIG. 6 shows the lateral profile of the field strength in the output waveguides of a 2×2 MMI as well as the profile of the field strength in the output plane for a conventional MMI.
FIG. 7 shows the lateral profile of the field strength in the output waveguides of a 2×2 MMI as well as the profile of the field strength in the output plane according to one exemplary embodiment of the present invention.
FIG. 8 shows the profile of the refractive index inside a 1×4 MMI for a known MMI and according to two different embodiments of the present invention.
FIG. 9 shows the lateral profile of the field strength in the output plane and in the output waveguides of a previously known 1×4 MMI.
FIG. 10 shows the lateral profile of the field strength in the output plane and in the output waveguides of a 1×4 MMI according to one exemplary embodiment of the present invention.
FIG. 11 shows the lateral profile of the field strength in the output plane and in the output waveguides of a 1×4 MMI according to another exemplary embodiment of the present invention.
FIG. 12 shows the lateral profile of the field strength in the output waveguides and in the output plane of a known 1×10 MMI.
FIG. 13 shows the lateral profile of the field strength in the output waveguides and in the output plane of a 1×10 MMI according to one exemplary embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows one exemplary embodiment of a known multimode interference coupler 100 . The MMI 100 is arranged on a substrate 106 . In this case, the substrate 106 may comprise a semiconductor substrate or a glass substrate, for example. A semiconductor substrate may contain, in particular, silicon and/or group III nitrides and/or a ternary or quaternary compound of elements from main group III and V and/or elements from main group II and VI. In this case, the substrate 106 may consist of a single compound or of a plurality of layers arranged on top of one another. The substrate may comprise lateral structuring. Further electronic and/or optical components may be arranged on the substrate.
The MMI comprises an active layer 104 which optionally adjoins a covering layer 107 and an intermediate layer 102 . In this case, the covering layer 107 and the intermediate layer 102 have, in particular, the task of providing a discontinuous refractive index profile in a direction z perpendicular to the surface of the substrate 106 , such that light propagating in the active layer 104 is totally internally reflected and cannot leave the layer 104 toward the top or bottom. The layer thickness of the active layer 104 is selected in this case in such a manner that only one mode is excited along the z axis.
In addition, the covering layer 107 may be designed to provide an inert surface in order to prevent the MMI 100 from being destroyed as a result of reacting with the surrounding atmosphere. The intermediate layer 102 may be additionally designed to adapt the lattice constants, to improve the adhesion of the layer 104 to the substrate 106 and/or may be designed as an etching stop layer.
The layer 104 may be produced, in particular, from a semiconductor material, a polymer or glass. The refractive index of the layer 104 can be set by changing the chemical composition and/or by means of doping.
The layer 104 has lateral structuring. This produces at least one supply waveguide 108 and at least one output waveguide 110 . A broader section 112 , in which a plurality of modes which are able to propagate can be excited and brought to interference, is situated between the supply waveguide 108 and the output waveguide 110 .
The layer 104 is designed in the region of the waveguides 108 and 110 and in the section 112 in such a manner that light guided inside the layer 104 cannot laterally leave the layer 104 in the x-y plane. In the exemplary embodiment illustrated, this is achieved by virtue of the layer 104 being surrounded by air which has a lower refractive index than the material of the layer 104 . In further embodiments of the invention, the layer 104 may also be surrounded by another material in the x-y plane.
During operation of the MMI, a plurality of modes in the region 112 are excited by the light wave which is injected using the waveguide 108 . Said modes come to interfere and form an interference image in the output plane 113 . Part of this interference pattern excites a single-mode output wave in the output waveguide 110 .
The example shown in FIG. 1 has one supply waveguide 108 and one output waveguide 110 . The exemplary embodiment shown is therefore referred to as a 1×1 MMI. MMIs may occasionally also have a plurality of supply and/or output waveguides. For example, 2×2 MMIs, 1×4 MMIs, 1×2 MMIs, 2×4 MMIs or 1×10 MMIs are customary.
The MMI 100 according to FIG. 1 may be part of an integrated circuit which comprises further optical and/or electronic components.
FIG. 2 shows the refractive index n(x) of an MMI on the ordinate and a spatial coordinate x on the abscissa in a direction running substantially perpendicular to the direction of the supply waveguide 108 . In the illustration selected in FIGS. 2-13 , the spatial coordinate x is standardized to the geometrical width W of a previously known MMI with the refractive index n 0 (x). In this case, FIG. 2 illustrates the profile of the refractive index at least in one section of the region 112 of the MMI 100 . In some embodiments of the invention, the refractive index profile illustrated is established over the entire propagation direction y of the region 112 .
The curve designated A illustrates the profile of the refractive index n 0 (x) of a known MMI. The refractive index profile according to A is constant in sections. This means that a first refractive index n 0 , 2.6 in the example illustrated, prevails in the region 112 of the MMI with the width W. A material having a second refractive index, 1.44 in the exemplary embodiment, is arranged to the right and to the left of the region 112 .
The invention now proposes configuring the refractive index n(x) as illustrated in curve B. The index profile optimized according to curve B has an alternating profile in the waveguide core, the amplitude between minima and maxima being smallest in the center of the waveguide. Outside the region 112 , the refractive index is somewhat raised in an edge layer toward the surrounding material.
In this case, the distance between two adjacent maxima or two adjacent minima is approximately 50 nm to approximately 400 nm. This distance is dependent on the wavelength and the geometrical dimensions of the region 112 . It is approximately 10% to approximately 50% of the wavelength of the radiation guided in the supply waveguide 108 .
FIG. 3 shows the effects of the refractive index profile according to FIG. 2 on the modes which are able to propagate. In this case, the ordinate in FIG. 3 shows the effective refractive index n eff . The number of modes m is plotted on the abscissa. In this case, the effective refractive index n eff is the average refractive index of the material in which the corresponding mode propagates. The effective refractive index n eff is therefore influenced by local or temporal inhomogeneities in the refractive index n(x).
In the case of a conventional waveguide with a refractive index (n(x)=n 0 ) which is constant in sections, the effective refractive index n eff of the respective mode is
n eff = n 0 · 1 - 1 2 · ( m + 1 ) 2 W em ,
where W em is the effective width of the region 112 of the MMI 100 that is standardized to the wavelength of the respective mode, n 0 is the constant refractive index of a stepped or box-shaped refractive index profile of a conventional MMI and m denotes the respective number of modes. This law is illustrated as curve A in FIG. 3 .
It was possible to show that the imaging properties of an MMI 100 are considerably improved if the following applies to the effective refractive index n eff :
n eff , m = n 0 · ( 1 - 1 2 · ( m + 1 ) 2 W n ) ,
where W n is the effective width of the region 112 of the MMI 100 which is standardized to the wavelength of the fundamental mode. The law illustrated above is illustrated as curve B in FIG. 3 . In the sense of the present invention, the effective width is understood in this case as meaning the width experienced by the modes which are able to propagate along their propagation path. This may be broader than the geometrical width W.
FIG. 3 shows that a profile of the effective refractive index according to curve A, which applies to a conventional MMI, differs from the inventive profile of the effective refractive index according to curve B. The magnitude of the difference increases with a greater number of modes m, with the result that these modes make only an incomplete contribution to the interference image in the output plane in a conventional MMI.
FIG. 3 also shows calculated values C (circles) for the effective refractive index of the first eight modes in an inventive waveguide having a refractive index profile according to FIG. 2 , curve B. As is clear from FIG. 3 , the calculated values C no longer differ from the optimum curve profile B.
In some embodiments, measured values for the points C according to FIG. 3 may differ in this case from the ideal profile B according to FIG. 3 on account of manufacturing tolerances when implementing the refractive index profile B according to FIG. 2 . Nevertheless, the effective refractive index profile implemented approximates the ideal profile in an improved manner in comparison with the previously used MMIs.
FIG. 4 shows the lateral profile of the field strength Φ(x) in the output plane 113 of the region 112 for the known 1×1 MMI illustrated in FIG. 1 . It is clear from FIG. 4 that the profile of the effective refractive index according to curve A in FIG. 3 results in higher-order modes not making an optimum contribution to the production of the interference image in the output plane 113 . Secondary maxima which cannot be injected into the output waveguide 110 at the point x=0 therefore form on both sides of the main maximum. The field strength of the output signal from the MMI 100 is therefore lower than the field strength of the input signal. In addition, the phase relationship between the output signal and the input signal can be adversely affected in an undesirable manner.
FIG. 5 shows the lateral profile of the field strength Φ(x) in the output plane 113 for an MMI having a refractive index profile according to the invention. As is clear from FIG. 5 , the field strength of the main maximum increases at the expense of the secondary maxima. A greater output power is thus available in the output waveguide 110 in the MMI proposed according to the invention.
FIGS. 6 and 7 show the lateral profile of the field strength Φ(x) in two outgoing waveguides (curve B) and in the output plane 113 (curve A) of a 2×2 MMI. In this case, the two MMIs have the same geometrical structure. The results illustrated in FIG. 6 apply to a known MMI, that is to say to an MMI having a refractive index profile according to curve A in FIG. 2 .
It is clear from FIG. 6 that the field strength Φ(x) in the output plane 113 of the MMI 100 according to curve A has, as desired, two main maxima which are approximately at the position of the output waveguides 110 . A secondary maximum which reaches approximately ⅔ of the field strength of the main maxima is located between the two main maxima. Toward the edge of the MMI, the field strength falls in a flatter manner than the local acceptance of the output waveguide 110 . In this manner, approximately ⅓ of the optical power in the output plane 113 cannot be injected into the output waveguides 110 . Furthermore, the optical power injected into the two waveguides differs by approximately 0.4 dB.
In contrast to this, FIG. 7 shows the field strength profile Φ(x) for an MMI having a refractive index profile proposed according to the invention. It is clear from curve A in FIG. 7 that the field strength of the main maxima increases in the output plane upon reducing the field strength of the secondary maxima on account of the refractive index profile proposed according to the invention. The field strength in the output plane (curve A) and the field strength in the output waveguide (curve B) are virtually congruent. This means that the radiated optical power is injected almost completely into the output waveguides 110 . The losses in the MMI are therefore lower at less than 0.1 dB. In addition, the difference between the field strengths injected into the two waveguides is negligible. The MMI proposed according to the invention thus allows an improved beam splitter.
FIG. 8 shows three different possible profiles of the refractive index n(x) for a 1×4 MMI with a width of 6 μm. In this case, the solid line A shows the refractive index profile of a known MMI. The associated interference image in the output plane of such an MMI is illustrated in FIG. 9 .
The line B illustrated using dashed lines shows the refractive index profile in one embodiment of the present invention. The refractive index B can be obtained by taking into account all modes which are able to propagate in the MMI as basic functions for calculating the refractive index profile. The interference image in the output plane of this MMI is illustrated in FIG. 10 .
In addition, FIG. 8 shows a further profile of the refractive index according to another embodiment of the present invention as a dotted line C. This profile of the refractive index can be obtained by including, in the calculation, only those basic functions which indicate the field strength distribution of modes which are able to propagate and are excited by the field of the supply waveguide to an extent above a predefinable limit value.
The practice of taking into account a sub-selection of modes which are able to propagate instead of all modes which are able to propagate results firstly in faster convergence of the proposed calculation method. Furthermore, the fluctuations of the refractive index and the amplitude of the resultant meanders are reduced. This makes it possible to reduce the manufacturing complexity. The interference image in the output plane of this MMI is illustrated in FIG. 11 .
Curve A in FIG. 9 shows the lateral profile of the field strength Φ(x) in the output plane 113 of a known 1×4 MMI 100 . The output power in the four output waveguides of the MMI is illustrated as curve B. The profile of the refractive index n(x) along the width of the MMI is constant in sections, as shown by the inserted curve profile in FIG. 9 .
The lateral profile of the field strength Φ(x) in the output plane shows four main maxima, as desired, but secondary maxima in between. The latter result in a loss of intensity. Furthermore, the field strength distribution between the main maxima is different, with the result that the known MMI divides the input power among four identical output waveguides only in an incomplete manner. The invention recognized that the interference pattern according to FIG. 9 has, in particular, deficits because higher-order modes have a phase error on account of the differing effective refractive index and therefore cannot properly contribute to the production of the interference pattern. This results in a loss of 0.5 dB and a disrupted equilibrium between the output waveguides of 0.6 dB (curve B).
FIG. 10 in turn shows the interference pattern in the output plane as curve A and the power injected into the output waveguides as curve B. The MMI according to FIG. 10 has the refractive index profile proposed according to the invention according to curve B in FIG. 8 , as is illustrated again in the inserted curve profile in FIG. 10 .
The interference pattern in the output plane according to FIG. 10 consequently exhibits a more uniform profile of the field strength of all four main maxima. The secondary maxima, which deprive part of the optical power of use, are present only in attenuated form in the interference pattern in FIG. 10 . The MMI according to the invention thus has a loss of 0.15 dB and a disrupted equilibrium between the output waveguides of 0.1 dB.
FIG. 11 in turn shows the interference pattern in the output plane as curve A and the power injected into the output waveguides as curve B. The MMI according to FIG. 11 has the refractive index profile proposed according to the invention according to curve C in FIG. 8 , as is illustrated again in the inserted curve profile in FIG. 11 .
It has surprisingly been shown that an improved signal quality in the output waveguides 110 can nevertheless be obtained by means of a simpler refractive index profile which can be obtained in a shorter calculation method and can be implemented with less complexity. The additional loss between the input power and the output power of the 1×4 MMI illustrated is thus only 0.1 dB in the case of the exemplary embodiment according to FIG. 11 . In this case, the maximum field strength in the inner waveguides is 0.12 dB lower than that in the outer waveguides.
FIGS. 12 and 13 finally show another exemplary embodiment of the MMI according to the invention. The field strength profile Φ(x) of a 1×10 MMI which divides the optical signal from a supply waveguide among ten output waveguides is illustrated. The interference region 112 required for this purpose has a width of 20 μm with a refractive index of n 0 =1.440.
FIG. 12 in turn shows the profile of the field strength in the output plane (curve A) and in the output waveguides (curve B) for a known 1×10 MMI with a refractive index which is constant in sections, as is illustrated in the inserted curve profile in FIG. 12 . The multiplicity of excited modes required by an interference pattern with 10 main maxima imposes great demands on the transmission behavior of the MMI in this case. These demands are only incompletely met by the known MMI. The sum of the output powers of the output waveguides is thus 1.16 dB lower than the injected power in the supply waveguide. The difference between the output waveguides with the strongest excitation and the output waveguides with the weakest excitation is 1.7 dB. Both the non-uniformity of the interference pattern and the high losses of the component are due to extensive secondary maxima which are established on account of the non-ideal propagation of higher-order modes in the waveguide.
By comparison, FIG. 13 shows the interference pattern in the output plane as curve A and the power injected into the output waveguides as curve B. The MMI according to FIG. 13 has the refractive index profile proposed according to the invention, as illustrated in the inserted curve profile in FIG. 13 .
In this case, it is clear from FIG. 13 that the secondary maxima have decreased considerably. The loss of the 1×10 MMI according to the invention accordingly reaches a value of 0.28 dB. The excitation uniformity in the output waveguides is also increased as desired. The difference between the output waveguides with the strongest excitation and the output waveguides with the weakest excitation is only 0.42 dB.
It goes without saying that the invention is not restricted to the exemplary embodiments illustrated. Rather, modifications and changes can be made when implementing the invention without substantially changing the invention per se. Therefore, the description above should not be considered to be restrictive but rather should be considered to be explanatory. The claims below should be understood in such a manner that a feature mentioned is present in at least one embodiment of the invention. This does not exclude the presence of further features. | A multimode interference coupler includes at least one supply waveguide and at least one output waveguide, wherein the coupler has along its longitudinal extent in the direction of the supply waveguide at least one longitudinal section in which the refractive index has a locally oscillating profile in a direction running substantially at right angles to the direction of the supply waveguide. A method for the structural configuration of such a multimode interference coupler. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 USC 119(a) of Korean Patent Application No. 10-2016-0003849 filed on Jan. 12, 2016 in the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference for all purposes.
BACKGROUND
[0002] 1. Field
[0003] The following description relates to a battery pack and a cooling method of a battery pack.
[0004] 2. Description of Related Art
[0005] A battery generates heat because an electrochemical reaction occurs in a process of using the battery. A battery should be maintained at a constant temperature in order to continuously use the battery for a long period of time. Therefore, a cooling device for absorbing generated heat may be provided at the battery.
[0006] A battery pack including multiple battery modules is commonly used to supply power in a large capacity system requiring high electrical power. Each battery module includes one or more battery cells, or batteries. Due to the amount of heat generated in such a battery pack, adequate cooling capability of a cooling device for the battery pack is important for stable operation of the system.
[0007] Generally, a cooling device is located outside a battery pack and cooling water is supplied from the cooling device with a serial or parallel structure to cool modules or cells inside the battery pack. However, a temperature difference between battery modules inside the battery pack may be generated and may cause a performance deviation and a lifespan deviation between the battery modules. Therefore, there is a need for an improved cooling structure and cooling operation to reduce a temperature deviation between modules.
SUMMARY
[0008] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0009] In one general aspect, a battery pack includes: battery modules; a cooling pipe connected to the battery modules; and one or more cooling units connected to the cooling pipe and configured to absorb heat from cooling liquid flowing inside the cooling pipe, wherein the battery modules and the one or more cooling units are disposed to alternate with respect to each other.
[0010] The battery modules and the one or more cooling units may be disposed to alternate with each other in a one-by-one order to enable the cooling liquid to flow through a cooling unit among the one or more cooling units after passing through a battery module among the battery modules.
[0011] The cooling pipe and the one or more cooling units may be connected to each other to form a closed loop.
[0012] The one or more cooling units may include a cooling unit disposed at a central position and the battery modules may include battery modules disposed in positions surrounding the central cooling unit.
[0013] The battery modules disposed in positions surrounding the central cooling unit may be disposed in upper, lower, left, right, and diagonal directions from the central cooling unit.
[0014] The central cooling unit may include layers of components that are vertically stacked and aligned.
[0015] The central cooling unit may further include a first heat exchanger disposed in a layer among the layers of components, and a second heat exchanger disposed in another layer among the layers of components. The cooling pipe may include a first loop configured to circulate the cooling liquid to a first battery module among the battery modules disposed in the positions surrounding the central cooling unit, and to exchange heat with the first heat exchanger, and a second loop configured to circulate the cooling liquid to a second battery module among the battery modules disposed in the positions surrounding the central cooling unit, and to exchange heat with the first heat exchanger and the second heat exchanger.
[0016] The cooling pipe and the one or more cooling units may form two or more closed loops in which to flow the cooling liquid.
[0017] The battery pack may further include a valve disposed between the battery modules and the one or more cooling units, and configured to control a flow of the cooling liquid.
[0018] The battery pack may further include a temperature sensor configured to measure a temperature of each of the battery modules.
[0019] The battery pack may further include: a valve; and a controller configured to control the valve based on the measured temperature of each of the battery modules.
[0020] The valve may include valves. The controller may be configured to control the valves to selectively configure the cooling pipe and the one or more cooling units to form one closed loop or closed loops through which the cooling liquid flows.
[0021] In another general aspect, a cooling method of a battery pack includes: measuring, by a sensor, a temperature of each battery module among battery modules; transmitting temperature information corresponding to the measured temperature of each battery module to a controller; generating, based on the temperature information, a valve control signal at the controller; and operating a valve according to the valve control signal to control a flow of cooling liquid through a cooling pipe to at least one of the battery modules.
[0022] In response to the temperature information indicating that the temperature of a selected battery module among the battery modules is higher than the temperatures of other battery modules among the battery modules, the operating of the valve may include operating the valve to cause the cooling liquid to flow through the selected battery module a greater number of times in a cooling cycle than the cooling liquid is caused to flow through the other battery modules in the cooling cycle.
[0023] Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a diagram illustrating a battery pack of a serial cooling structure.
[0025] FIG. 2 is a diagram illustrating a battery pack of a parallel cooling structure.
[0026] FIG. 3 is a schematic diagram for describing a serial cooling structure of a battery pack.
[0027] FIG. 4 is a schematic diagram for describing a parallel cooling structure of a battery pack.
[0028] FIG. 5 is a schematic diagram of a battery pack, according to an embodiment.
[0029] FIG. 6 is a diagram illustrating an example of a flow of cooling water in the battery pack shown in FIG. 5 .
[0030] FIG. 7 is a diagram illustrating a flow of cooling water in a battery pack, according to another embodiment.
[0031] FIG. 8 is a diagram illustrating a flow of cooling water in a battery pack, according to another embodiment.
[0032] FIG. 9 is a diagram illustrating a flow of cooling water in a battery pack, according to another embodiment.
[0033] FIG. 10 is a diagram illustrating a flow of cooling water in a battery pack, according to another embodiment.
[0034] FIG. 11 is a diagram illustrating a flow of cooling water in a battery pack in which a cooling unit is configured in a plate shape, according to an embodiment.
[0035] FIGS. 12A and 12B are diagrams illustrating a flow of cooling water in a battery pack, according to another embodiment.
[0036] FIGS. 13A-13D are diagrams illustrating a flow of cooling water in battery packs, according to other embodiments.
[0037] FIG. 14 is a diagram illustrating a cooling method of a battery pack, according to an embodiment.
[0038] FIG. 15 is a diagram illustrating a cooling method of a battery pack, according to another embodiment.
[0039] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals should be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.
DETAILED DESCRIPTION
[0040] The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses, and/or systems described herein. However, various changes, modifications, and equivalents of the methods, apparatuses, and/or systems described herein will be apparent after an understanding of the disclosure of this application. For example, the sequences of operations described herein are merely examples, and are not limited to those set forth herein, but may be changed as will be apparent after an understanding of the disclosure of this application, with the exception of operations necessarily occurring in a certain order. Also, descriptions of features that are known in the art may be omitted for increased clarity and conciseness.
[0041] The features described herein may be embodied in different forms, and are not to be construed as being limited to the examples described herein. Rather, the examples described herein have been provided merely to illustrate some of the many possible ways of implementing the methods, apparatuses, and/or systems described herein that will be apparent after an understanding of the disclosure of this application.
[0042] Throughout the specification, when an element, such as a layer, region, or substrate, is described as being “on,” “connected to,” or “coupled to” another element, it may be directly “on,” “connected to,” or “coupled to” the other element, or there may be one or more other elements intervening therebetween. In contrast, when an element is described as being “directly on,” “directly connected to,” or “directly coupled to” another element, there can be no other elements intervening therebetween.
[0043] As used herein, the term “and/or” includes any one and any combination of any two or more of the associated listed items.
[0044] Although terms such as “first,” “second,” and “third” may be used herein to describe various members, components, regions, layers, or sections, these members, components, regions, layers, or sections are not to be limited by these terms. Rather, these terms are only used to distinguish one member, component, region, layer, or section from another member, component, region, layer, or section. Thus, a first member, component, region, layer, or section referred to in examples described herein may also be referred to as a second member, component, region, layer, or section without departing from the teachings of the examples.
[0045] Spatially relative terms such as “above,” “upper,” “below,” and “lower” may be used herein for ease of description to describe one element's relationship to another element as shown in the figures. Such spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, an element described as being “above” or “upper” relative to another element will then be “below” or “lower” relative to the other element. Thus, the term “above” encompasses both the above and below orientations depending on the spatial orientation of the device. The device may also be oriented in other ways (for example, rotated 90 degrees or at other orientations), and the spatially relative terms used herein are to be interpreted accordingly.
[0046] The terminology used herein is for describing various examples only, and is not to be used to limit the disclosure. The articles “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “includes,” and “has” specify the presence of stated features, numbers, operations, members, elements, and/or combinations thereof, but do not preclude the presence or addition of one or more other features, numbers, operations, members, elements, and/or combinations thereof.
[0047] Due to manufacturing techniques and/or tolerances, variations of the shapes shown in the drawings may occur. Thus, the examples described herein are not limited to the specific shapes shown in the drawings, but include changes in shape that occur during manufacturing.
[0048] The features of the examples described herein may be combined in various ways as will be apparent after an understanding of the disclosure of this application. Further, although the examples described herein have a variety of configurations, other configurations are possible as will be apparent after an understanding of the disclosure of this application.
[0049] FIGS. 1 and 2 illustrate example battery packs, and FIGS. 3 and 4 are schematic diagrams for describing example cooling structures of the battery packs of FIGS. 3 and 4 , respectively.
[0050] With reference FIGS. 1 and 3 , a serial cooling structure of a battery pack will be described. In an example, cooling water discharged from a cooling device 30 flows and circulates through battery modules 10 to absorb heat from the battery modules 30 , and then flows back to the cooling device 30 . However, in the serial cooling structure, a temperature difference between battery modules 10 disposed at a position at which the cooling water just discharged and flowing away from the cooling device 30 flows and battery modules 10 disposed at a position at which the cooling water circulated one time and flowing back into the cooling device 30 flows may occur, due to an increasing temperature of the cooling water along the serial cooling pathway. In other words, a temperature difference between a battery module 10 located in the vicinity of a cooling water inlet and a battery module 10 located in the vicinity of a cooling water outlet may occur. As described above, in such a serial cooling structure, the battery modules 10 are not uniformly cooled. Consequently, a battery pack of a serial cooling structure may have unsatisfactory operation stability.
[0051] In a different example, in a battery pack of a parallel cooling structure shown in FIGS. 2 and 4 , a cooling deviation between the battery modules 10 due to a variation in a temperature of the cooling water along the cooling pathway may not occur, but a difference in a length of portions of a cooling pipe 20 which supply the cooling water from the cooling device 30 to each of the battery modules 10 may exist, thereby causing deviations in a flow rate of the cooling water at locations of the cooling pathway corresponding to the battery modules 10 . Thus, a battery pack of a parallel cooling structure may have unsatisfactory operation stability.
[0052] FIG. 5 is a schematic diagram of a battery pack 100 for a uniform cooling of battery modules, according to an embodiment. With reference to FIG. 5 , the battery pack 100 includes battery modules 10 and cooling units 40 .
[0053] A battery module 10 is, for example, a battery assembly in which battery cells (not shown) are grouped in a predetermined number to be inserted into a frame so as to protect the battery cells from an external impact, heat, vibration and the like. A battery module 10 may be configured with about ten battery cells and may be a lithium ion battery. However, a battery module 10 is not limited to having a particular number of cells or having a particular construction or composition.
[0054] The cooling pipe 20 through which cooling water flows extends in, through or adjacent to the battery modules 10 . The cooling water flowing in the cooling pipe 20 absorbs heat generated by the battery modules 10 so that the battery modules 10 are cooled. Therefore, the battery modules 10 may be maintained at a constant temperature even though it is used continuously for a long time. The cooling pipe 20 may be attached and disposed outside the battery modules 10 using an adhesive member. However, the cooling pipe 20 may have any shape and may be attached to or near the battery modules 10 in any suitable manner, so long as the cooling pipe 20 is disposed at the battery modules 10 .
[0055] The cooling units 40 are connected to the cooling pipe 20 to absorb heat of the cooling water flowing in the cooling pipe 20 . The cooling water absorbing the heat of a battery module 10 flows into an inlet of a respective cooling unit 40 connected to the cooling pipe 20 . The cooling water flowing into a cooling unit 40 is cooled by radiating heat in the cooling unit 40 . Consequently, the cooling water discharged from an outlet of a cooling unit 40 absorbs heat of a battery module 10 disposed downstream of the cooling unit 40 . A cooling unit 40 may cool the cooling water using a refrigerant which circulates through a cooling circuit of the cooling unit 40 composed of a heat exchanger, a compressor, a condenser, and an expansion valve, and a unit for cooling the cooling water through air cooling.
[0056] The battery modules 10 and the cooling units 40 are alternately disposed with each other. Thus, a temperature deviation between the battery modules 10 is minimized by enabling the cooling water, which absorbs heat of one battery module 10 and rises in temperature, to flow to a cooling unit 40 disposed downstream of the one battery module 40 and then be cooled and directed to another battery module 10 , instead of immediately flowing to another battery module 10 without being cooled. As a result, operational stability of the battery pack 100 is enhanced. Also, the sections of the cooling pipes 20 which respectively supply the cooling water to each of the battery modules 10 have a same length. Consequently, a deviation of a flow rate of the cooling water among the sections of the cooling pipe 20 battery modules is prevented or minimized.
[0057] The battery modules 10 and the cooling units 40 are alternately disposed one by one in FIG. 5 so as to enable the cooling water to flow to a cooling unit 40 after passing a single battery module 10 . However, as shown in FIGS. 13A-13D , a battery pack may be configured to enable the cooling water to pass and cool one, two, three, or four battery modules and then to feed back to the cooling unit. In the examples of FIGS. 13A-13D , a structure of a battery pack may be simplified to reduce a size of the battery pack 100 .
[0058] For example, in FIGS. 13A-13D , respective battery packs 100 f - 100 i , according to additional embodiments, include a cooling pack 40 disposed at a central position and battery modules 10 disposed at perimeter positions around the cooling pack 40 . In the battery pack 100 f of FIG. 13A , a cooling pipe 20 includes a loop passing through one battery module 10 , and is configured to enable cooling water to pass and cool the one battery module 10 and then feed back to the cooling pack 40 . In the battery pack 100 g of FIG. 13B , a cooling pipe 20 includes a loop passing through two battery modules 10 , and is configured to enable cooling water to pass and cool the two battery modules 10 and then feed back to the cooling pack 40 . In the battery pack 100 h of FIG. 13C , a cooling pipe 20 includes a loop passing through three battery modules 10 , and is configured to enable cooling water to pass and cool the three battery modules 10 and then feed back to the cooling pack 40 . In the battery pack 100 i of FIG. 13D , a cooling pipe 20 forms a loop passing through four battery modules 10 , and is configured to enable cooling water to pass and cool the four battery modules 10 and then feed back to the cooling pack 40 .
[0059] FIG. 6 illustrates a flow of the cooling water in the battery pack shown in FIG. 5 , FIG. 7 illustrates a flow of cooling water in a battery pack 100 a , according to another embodiment, and FIG. 8 illustrates a flow of cooling water in a battery pack 100 b , according to another embodiment. As shown in FIGS. 6 to 8 , a cooling pipe 20 and cooling units 40 , which are disposed in alternating sequence with the battery modules 10 , are integrally connected to each other to form a single closed loop, or two or more closed loops.
[0060] The battery pack 100 a of FIG, 7 has the same configuration of battery modules 10 and cooling units 40 provided in the battery pack 100 of FIGS. 5 and 6 . However, in the battery pack 100 a of FIG. 7 , a valve group 50 and a controller (not shown) configured to control the valve group 50 are provided to control a flow of the cooling water. The valve group 50 is disposed between a second battery module 10 and a third cooling unit 40 disposed downstream from the second battery module 10 , and includes a plurality of valves. The valves may be solenoid valves which are opened and closed by an electromagnetic force of a coil. By opening or closing certain valves, a single closed loop of the cooling pipe 20 may be integrally formed or two closed loops of the cooling pipe 20 may be formed.
[0061] The battery pack 100 b is similar to the battery pack 100 a of FIG. 7 , except that the battery pack 100 b includes three valve units 50 , each including a plurality of valves. More specifically, a first valve group 50 is disposed between a first battery module 10 and a second cooling unit 40 disposed downstream from the first battery module 10 , a second valve group 50 is disposed between a second battery module 10 and a third cooling unit 40 disposed downstream from the second battery module 10 , and a third valve group 50 is disposed between a third battery module 10 and a fourth cooling unit 40 disposed downstream from the third battery module 10 . By opening or closing certain valves, a single closed loop of the cooling pipe 20 may be integrally formed, or two, or three closed loops of the cooling pipe may be formed. It can be appreciated from the example embodiments of FIGS. 6-8 that any number of battery modules 10 and cooling units 40 may be provided and various numbers and arrangements of valve groups 50 may be provided in order to provide a variable number of closed loops in the cooling pipe 20 .
[0062] Alternatively, the battery packs 100 a and 100 b are partially cooled by controlling the valves. In this case, active cooling may be possible according to a load status so that efficiency of cooling may be improved. Also, a partial cooling is possible so that a capacity of a pump may be reduced and a power requirement may be reduced in comparison to full cooling of the battery pack 100 a or 100 b.
[0063] FIG. 9 illustrates a flow of cooling water in a battery pack 100 c for a uniform cooling of battery modules 10 , according to another embodiment. FIG. 10 illustrates a flow of cooling water in a battery pack 100 d for a uniform cooling of battery modules 10 , according to another embodiment.
[0064] With reference to FIGS. 9 and 10 , in the battery packs 100 c and 100 d , a cooling unit 40 is disposed at a central position, and battery modules 10 are disposed in a pattern surrounding the cooling unit 40 . In the battery pack 100 c, the battery modules 10 are disposed in upper, lower, left, and right directions from the cooling unit 40 . In the battery pack 100 d , the battery modules 10 are disposed in upper, lower, left, right, and diagonal directions from the cooling unit 40 . In the battery packs 100 c and 100 d , loops of the cooling pipe 20 are disposed between the cooling unit 40 and each battery module 10 . The battery packs 100 c and 100 d may be configured such that cooling water flows, in one loop of the cooling pipe 20 , from the cooling unit 40 to one battery module 10 and then back to the cooling unit 40 , then subsequently flows, in a next loop of the cooling pipe 20 , to a next battery module 10 and then back to the cooling unit 40 , and so on. In other words, the cooling unit 40 and the loops of the cooling pipe 20 may form a continuous cooling circuit in which each battery module is cooled by cooling water flowing directly from the cooling unit 40 and each cooling water exiting each battery module 10 flows directly to the cooling unit 40 . Therefore, a refrigerant circulates through peripheral battery modules 10 to absorb heat from the battery modules 10 , and flows to the cooling unit 40 located at the central position.
[0065] As described above, when the cooling unit 40 is located at the central position and the battery modules 10 are disposed to surround the cooling unit 40 , there are advantages in that the battery modules 10 may be uniformly cooled and a size of the battery pack 100 c / 100 d may be reduced in comparison to conventional battery packs.
[0066] FIG. 11 illustrates a flow of cooling water in a battery pack in which a cooling unit 40 is configured in a plate shape. As shown in FIG. 11 , the cooling unit 40 includes vertically stacked and aligned layers of components. For example, the cooling unit 40 includes one or more heat exchangers 45 , compressors, condensers, and expansion valves, and the one or more heat exchangers 45 are configured in a plate shape and arranged in a stack with the one or more compressors, condensers, and expansion valves. Therefore, heat exchange may be performed between layers adjacent to each other. That is, in an example, cooling water which circulates in a first loop of a cooling pipe 20 , through one battery module 10 , and in a first layer of the cooling unit 40 , exchanges heat with a heat exchanger 45 of a second layer of the cooling unit 40 , and cooling water which circulates in a second loop of the cooling pipe 20 , through another battery module 10 , and in a third layer of the cooling unit 40 , exchanges heat with the heat exchanger 45 of the second layer and a heat exchanger 45 of a fourth layer of the cooling unit 40 . Thus, the cooling water in the first and second cooling pipes 20 is cooled.
[0067] FIGS. 12A and 12B illustrate a flow of cooling water in a battery pack 100 e, according to another embodiment. As shown in FIGS. 12A and 12B , a cooling unit 40 is disposed at a central position, and battery modules 10 are disposed in a pattern surrounding the cooling unit 40 . Cooling water circulating in upper, lower, left, and right directions from the cooling unit 40 and cooling water circulating in diagonal directions from the cooling unit 40 form closed loops different from each other. That is, a first loop of the cooling pipe 20 is configured to circulate cooling water in the upper, lower, left, and right directions, and a second loop of the cooling pipe 20 is configured to circulate cooling water in the diagonal directions. A particular battery module 10 located at a position requiring cooling may be cooled through the operation of a controller and a valve controlled by the controller. Thus, active cooling based on a load status is possible so that efficiency of cooling may be improved.
[0068] FIG. 14 illustrates a cooling method of a battery pack 200 , according to an embodiment. As shown in the sequence of views in FIG. 14 , in the battery pack 200 , battery modules 10 are cooled in a fixed order of 1 → 2 → 3 → 1 → 2 . . . , regardless of a load status and an operating circumstance. However, such a cooling method may have difficulty in actively responding to an occurrence of a temperature deviation between the battery modules 10 . Also, since cooling is continuously performed regardless of a load, energy efficiency is not optimized.
[0069] FIG. 15 illustrates a cooling method of a battery pack 300 , according to another embodiment. First, a temperature sensors measure a temperature of each battery module 10 . A temperature sensor may be attached to each of the battery modules 10 so as to measure a temperature thereof. The temperature sensor may be a temperature measuring resistor or a thermistor, but it is not limited thereto, and the temperature sensor may be any kind of temperature sensor.
[0070] Then, measured temperature information of each of the battery modules 10 is transmitted to a controller. The temperature information may be transmitted by a wired or wireless communication.
[0071] Next, the controller generates a valve control signal in response to receiving the temperature information. More specifically, the controller, in response to receiving the temperature information of each of the battery modules, derives an optimal flow of cooling water through an arithmetic operation. The controller then generates ON/OFF (e.g., open/close) control signal of a valve to enable the cooling water to perform the optimal flow.
[0072] Thereafter, the valve operates according to the valve control signal of the controller. The valve may be a solenoid valve which is opened and closed by an electromagnetic force of a coil so as to enable the valve to be operated according to the valve control signal of the controller. The cooling water flows to cool each of the battery modules 10 in communication with the flow of the cooling water determined by the valve control signal.
[0073] Therefore, as shown in FIG. 15 , for example, when a second battery module 10 generates significantly more heat than other battery modules 10 , the cooling water flows in an order of 2 → 1 → 2 → 3 . . . (where the numbers 1 , 2 and 3 correspond to first, second and third battery modules) to cool the second battery module 10 more than the other battery modules 10 . That is, within a cooling cycle of the battery pack 300 , the cooling water flows to the second battery module 10 a greater number of times than the cooling water flows to the other battery modules 10 .
[0074] When following the method disclosed above, active cooling may be performed according to a status of the battery module 10 so that efficiency of cooling may be improved. Also, a partial control may be possible so that a capacity of a pump may be miniaturized and a power requirement may be reduced.
[0075] It is noted that, while various disclosure describes cooling of a battery pack in various embodiments by using “cooling water,” cooling liquids other than water may be used.
[0076] While this disclosure includes specific examples, it will be apparent after an understanding of the disclosure of this application that various changes in form and details may be made in these examples without departing from the spirit and scope of the claims and their equivalents. The examples described herein are to be considered in a descriptive sense only, and not for purposes of limitation. Descriptions of features or aspects in each example are to be considered as being applicable to similar features or aspects in other examples. Suitable results may be achieved if the described techniques are performed in a different order, and/or if components in a described system, architecture, device, or circuit are combined in a different manner, and/or replaced or supplemented by other components or their equivalents. Therefore, the scope of the disclosure is defined not by the detailed description, but by the claims and their equivalents, and all variations within the scope of the claims and their equivalents are to be construed as being included in the disclosure. | A battery pack includes: battery modules; a cooling pipe connected to the battery modules; and one or more cooling units connected to the cooling pipe and configured to absorb heat from cooling liquid flowing inside the cooling pipe, wherein the battery modules and the one or more cooling units are disposed to alternate with respect to each other. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in broad terms to the operation of a circuit, as a token card, in an access control system, and in similar applications. The invention is also concerned with a method of performing a transaction on a circuit, and with a circuit which can be programmed for a particular service and which can be loaded or reloaded with tokens. The invention relates specifically to integrated circuits (IC's) for such cards, and to IC's which can be used for access control encoders operating via various communication media such as infrared, inductive coupling, RF or microwave links.
2. Discussion of the Background
Existing smart card technology can be divided into memory based systems and more complex microprocessor based systems. These systems have been applied to different applications of electronic money transfer and cash cards. The need for an electronic payment medium for high volume transactions and relatively low monetary value per transaction has demanded inexpensive disposable cards.
The general areas of application of memory based smart cards are public telephones, commuting systems, domestic energy distribution and vending systems, access control and authentication. In these applications the service providers usually provide facilities in units of payment. These smart cards are therefore referred to as token cards. The cards are usually not interchangeable between different services or service providers and are programmed for a particular type of service and a specific service provider.
With the rapid growth which is taking place towards prepaid cashless transactions, existing token card systems are becoming less acceptable due to their limited functionality as well as the lack of built-in security mechanisms. Considerations in the usage of token cards are the cost per token, the number of tokens which are programmed per card, the possible frequency of use and the ease of use. In order to keep the cost of token cards as low as possible the security, and thus the complexity, of these cards have been overlooked. The security aspect has become contentious as token card fraud becomes easier with changes in technology. An additional requirement in some applications is the ability to recharge or reload a card with tokens, a factor which has proved to be a major obstacle.
A so-called link-based token card has been in use for a number of years round the world in card-based payphone systems. The technology which is used provides the capability of an alterable structure on silicon and the tokens are implemented as respective intact fuses.
A card of this type is programmed by an issuer with the required number of fuses or tokens intact. One unit of service is granted by a service provider after a link or fuse has been successfully removed or blown on the card. The link-based token card is uncomplicated and cost effective to implement. Tokens are represented in a straightforward manner. This type of card is compatible with technology available a few years ago. Once all the links have been fused the card can only be discarded making it impossible to reload the card. This prevents illegal reloading. The fusing action is usually permanent making the reloading of a specific card impossible or at least non-viable.
On the other hand a link-based token card does exhibit certain disadvantages, particularly in the security area. The cards are all the same and no means of identification of a specific card exists, rendering service auditing impossible. Electronic fraud is easy as a valid card can either be cloned or transactions can be recorded and replayed between a terminal and a valid card. This action is not traceable and thus cannot be detected nor prevented. A card cannot be blacklisted because the cards are not numbered and so are not individually identifiable.
To limit fraud and add to the functionality of the link-based card a secure logic memory chip solution has been developed.
The link-based system has a one-to-one relationship between tokens and links, requiring a memory area the extent of which is directly related to the number of tokens on the chip. With the introduction of non-volatile memory it has become possible to represent the number of remaining tokens in a more compact way. Tokens on a card can be held in one or more counters that will only be decremented and, once exhausted, the card is discarded. The problem remains however that the information on the card's IC is in the open and can easily be read and used to commit fraud.
Security related enhancements to this type of IC are accomplished by using an IC identification number, secret codes stored on the IC, and verification data unique to an IC.
The secure logic memory IC is manufactured in three stages, namely the manufacturer stage, the issuer stage and the user stage.
During the manufacturing or the first stage, a card IC receives a unique identity or serial number. This information is stored in PROM-type memory and cannot be altered during the lifetime of the IC. This enables transactions which are performed using the card to be monitored.
The card with the IC leaves the manufacturing stage with a secret batch or transport code stored in non-readable memory. In the second or issuer stage the card is placed in the issuer mode by successful presentation of the transport code. This prevents the manufacturing of unauthorized cards. The required number of tokens is now loaded into the card. The card then enters the third or user stage by blowing a fuse, disabling the reloading of tokens.
A secret derived number is calculated using an issuer specific function and the IC or card serial number and is stored on the card. When the card is used at a terminal, this number is calculated by the terminal using the serial number to determine if a legitimate card has been presented. This offers some degree of verification of the card since the secret derived number cannot be changed nor recalculated.
These cards offer a number of advantages. The number of tokens on a card is represented in a more compact way leaving more silicon area for additional functions. The transport code provides protection against the fraudulent loading of tokens. Card tracking is possible as each card contains a unique serial number and a blacklist can be downloaded to each terminal, eliminating the use of an unauthorized card. The derived card number stored on each card makes it difficult to falsify a card as the user cannot calculate the derived number from the serial number if the algorithm is unknown.
On the other hand these cards do suffer from certain disadvantages. Fraud detection and the administering of blacklisting facilities can often prove to be impractical. The cloning of a card is relatively easy as all the data on the card can be read directly. Transaction sequence replay between a terminal and a card is still possible as the replay and the reaction of a valid card cannot be distinguished from one another.
International standards prescribe the physical format and the electronic interface of token cards. Communication between a smart card and a reader is via an electronic interface. This interface is prescribed by the International Standards Organization (ISO) and the standard normally applied is ISO 7816.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of performing a transaction on a circuit, which may be an IC, which offers increased security.
It is a further object of the invention to provide a circuit, which may be an IC, for use, for example, in a token card.
The invention provides, in the first instance, a method of performing a transaction on a circuit which includes the steps of:
a) presenting the circuit to a terminal;
b) transferring a challenge and a decrement command from the terminal to the circuit;
c) implementing the decrement command on the circuit;
d) if the decrement command has been successfully implemented, transferring a response from the circuit to the terminal;
e) validating the response; and
f) if the response is valid, accepting the transaction.
The challenge may include a number which is at least partly random, and may include a command or other information.
The response may be an encoded value produced by an algorithm operating on a secret derived key, the challenge and other information, e.g. a counter on the circuit. The secret derived key may be derived from the circuit serial number and an issuer's key. When the memory map or other information on the circuit is used along with a challenge, the response represents a hashing function, or a form of electronic signature, of the information on the circuit.
The encoding function that is referred to in this description can be a linear or non-linear encoding function, or an encryption function, and may be represented by the equation:
f.sub.encode (Secret or derived key, (serial number or challenge))=encoded information.
The preferred encoding function is a non-linear function. This type of function is often used in the field of cryptography and is usually chosen for its characteristics which prevent or at least inhibit the prediction of the input, even if the output is known.
The response may be validated by transferring a serial number from the circuit to the terminal, performing an encoding function on the transferred circuit serial number and on an issuer's key to produce a secret derived key, performing an encryption function using the secret derived key on the challenge and other information, and comparing the encoded output to the transferred response.
The decrement command may cause the decrementing of a required number of tokens on the circuit. The decrement command may be regarded as having been successfully implemented if the required number of tokens is in fact available on the circuit and if the number of tokens is decremented in accordance with the decrement command.
The circuit may be reloaded with tokens by transferring to the circuit a derived validation key, comparing the transferred derived validation key to a derived validation key still on the circuit and, if the comparison is acceptable, opening the circuit for the reloading of tokens.
The circuit may initially carry a transport code which may be specific to an issuer and which permits the issuer to load tokens onto the card during an initial stage. The transport code may be replaced by the derived validation key to prevent unauthorized programming or reloading of the circuit if the transport code becomes known.
The invention also provides a circuit which includes:
storage means for storing a serial number;
storage means for storing a secret derived key derived from the serial number, an issuer's key and a first encoding function; token counter means;
interface means for receiving a challenge and a decrement command;
means for decrementing the count in the token counter means in response to the decrement command;
means, in response to a successful count decrement, for producing an encoded value, from the secret derived key, the challenge and a second encoding function;
means for providing an encoded response based on the challenge, a key, an algorithm and information on the circuit or any subset thereof; and
means for presenting the encoded value to the interface means.
One aspect of the invention provides for a token from a circuit to be accepted as valid, the deduction of a token from the circuit must be authenticated and the circuit must be authenticated. The method of the invention is based on the manipulation of a challenge and response procedure and provides information that a valid token has been securely, i.e. successfully, deducted. If the challenge and response are correlated then the validity of the circuit is proven and the token transaction is accepted.
In one embodiment the validation process makes use of the property that the response to a challenge is unique and different for each circuit and the relationship between a response and challenge is kept secret through a secret key mechanism. The possibility of obtaining the correct response by chance is kept small by using a large numeric value for the challenge and the response. An acceptable numeric value for the challenge and response consists of 32 bits, providing a chance which is less than one in four thousand million of inadvertently or unlawfully correlating the challenge and the response. Also, the challenge must not be predictable.
In a particular embodiment of the invention the challenge is handled by way of a counter on the circuit. The counter runs under control of the terminal either through a synchronous clock signal or under an oscillator on the circuit. For a duration from the time it is activated (no activity when off) until the terminal signals it to stop, the card may output information about the counter status as it is running.
The advantage of such a challenge mechanism is the ease with which the challenge is transferred. An almost unidirectional challenge/response (IFF) system is created i.e. from circuit to terminal.
Another embodiment of the invention provides for a challenge to be generated based on the period of activation and a response to be output during the next activation.
In a further embodiment the circuit first transmits a response and then receives or forms a challenge that is used the next time it is activated. However, this mechanism does represent some security risk. Between activations the challenge information may be stored in non-volatile memory such as EEPROM or volatile memory with backed up power.
For access control applications, the response may be based on the challenge and a counter (see SA patent No. 91/4063; U.S. application Ser. No. 08/01 9821 now U.S. Pat. No. 5,517,187) that is related to the number of times that the circuit has been activated.
In more general terms the invention provides a method of operating a circuit which includes the steps of accepting a challenge, and generating a first response to the challenge using a first algorithm which operates on at least the challenge and a secret key derived from information relating to the circuit.
In one embodiment the challenge is generated, and accepted, by the circuit, and a corresponding challenge is generated externally of the circuit.
The challenge may be generated by means of counter means in the circuit. The counter means may be controlled at least partly by means which is external to the circuit.
Alternatively the challenge is generated externally of the circuit and is then accepted by the circuit.
The challenge may include at least one of the following:
a number which is at least partly random, a command, and data relating to the circuit.
The information relating to the circuit may be identity information, such as a serial number.
The method may include the steps of transmitting the first response to a terminal which is external to the circuit and, at the terminal, of generating a second response using at least data relating to the circuit, obtained from the first response.
The second response may be generated by the operation of the first algorithm on the challenge and on a second key derived at least from the said obtained data relating to the circuit. Preferably the second key is derived by the operation of a second algorithm on the said information relating to the circuit and on an issuer's key which is stored at the terminal.
The method may include the steps of comparing the second response to the first response and, depending an the outcome of the comparison, validating or rejecting the first response.
When applied to a token transaction, the method may include the steps of storing a token count in the circuit, issuing a token count decrement command to the circuit, and only generating the said first response if the token decrement command is successfully carried out.
The invention also provides a method of programming a circuit which includes the steps of:
storing in the circuit a secret transport code which is not readable from outside the circuit;
presenting a transport code to the circuit;
comparing the presented transport code to the secret transport code, and, if the presented transport code is acceptable, carrying out at least one of the following:
storing application specific information in the circuit;
storing a token counter value in the circuit;
storing in the circuit a secret derived key which is derived using information specific to the circuit and a user defined function; and
replacing the secret transport code with a derived validation key.
The invention also extends to a method of operating a token card which includes the steps of:
a) on the card, storing a card serial number, a token count and a first secret key derived from at least the card serial number,
b) at a terminal, storing a card issuer's key,
c) presenting the card to the terminal,
d) at the terminal, reading the card serial number, and issuing to the card a challenge and a token count decrement command,
e) on the card, if the token count decrement command is successfully carried out, operating a first algorithm on the first secret key and the challenge to produce a first response,
f) transferring the first response to the terminal,
g) at the terminal, operating the first algorithm on the challenge and on a second key derived from at least the card issuer's key and information obtained from the transferred first response, to produce a second response, and
h) at the terminal, comparing the transferred first response to the second response.
The invention also provides a circuit which includes means for accepting a challenge, and means for generating a first response to the challenge using a first algorithm which operates on at least the challenge and a secret key derived from information relating to the circuit.
The circuit may include means such as a counter for generating the challenge.
The counter may be at least partly externally controlled.
The circuit may include means for storing a token count and means for receiving a token count decrement command and control means for generating the said first response only if the token decrement command is successfully carried out.
The circuit may be provided in any suitable form, e.g. as an integrated circuit which may be bonded to a card to form a secure token card.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a block diagram of an IC according to the invention,
FIG. 2 is a block diagram illustrating the operation of an IC and a terminal, and
FIG. 3 is a memory map of an IC according to the invention showing memory variables that can be defined and altered at manufacturing, issuing and user stages in the cycle of the IC.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to FIG. 1 of the accompanying drawings, the IC 1 of the invention includes a memory 10, such as a 256 bit non-volatile random access memory (RAM), preferably using EEPROM technology.
FIG. 3 shows a map 12 of the memory area, which is divided into sections which include storage 14 for a secret derived key 16, storage 18 for a transport code 20 or derived validation key 20A, a lock indicator area 22, storage 24 for a manufacturer's code 26, storage 28 for a card serial number 30, an area 32 for a token count 34, and an application or utility area 36.
The numbers of bits used for each element are given as practical examples in this description. The bit lengths are chosen short enough to ensure that the implementation is practical to realize, but long enough to be secure for the applications for which the invention is intended.
For this embodiment, the secret derived key 16 uses 64 bits of memory. The transport code 20 or derived validation key 20A uses 64 bits with 16 bits overlapping with 16 bits of the secret derived key. The overlapping portion is indicated by hatching 38.
The lock indicator area 22 is used to indicate if the card is locked for access from outside or not and uses 16 bits.
The manufacturers code 26 comprises 16 bits and contains a secret code which is used to prevent the issuing of IC's by unauthorized manufacturers.
The IC serial number 30 consists of 48 bits.
The area 34 consists of 48 bits and stores the number of tokens issued by an issuer as well as an error correction procedure 40, see FIG. 2, that operates on the token counter area to ensure reliable token counter operation.
The application or utility area 36 consists of 16 bits and is used for general IC detail or particulars pertaining to an application.
Referring to FIG. 1, the IC includes a serial interface 42 which provides a standard ISO 7816-3 interface 43 to the IC, consisting of serial synchronous write information to the IC or serial synchronous read information from the IC. The interface also includes provision 44 for clock information for the IC.
Commands which can be input to the IC via the serial interface 43 include reset e.g. on power up, read from, write to, submit transport code to, decrement token on, primary validate and secondary validate. The commands are issued conforming to a defined protocol.
The timing of internal and external electrical signals is controlled by an on-chip oscillator 46.
A power-on reset circuit 48 is provided to reset the circuit of the IC at power-on to ensure that the IC's circuits are in a known state when it is activated. The circuit 48 also ensures that the IC is not functional below a predetermined supply voltage.
A counter and error correction function is carried out by a module 50. The IC also includes processing means 52 for carrying out a validation encoding function--see FIG. 2. The encoding function that is referred to in this description can be a linear or nonlinear function or an encryption function.
FIG. 2 is a block diagram illustrating the operation of the IC in conjunction with a IC reader or terminal. The serial interface 42 of the IC is positioned on a center line of FIG. 2. Components to the left of the serial interface are associated with the terminal while the components on the right of the serial interface are associated with the IC.
In FIG. 2 like reference numerals are used to indicate items which are similar to the corresponding items described in connection with FIGS. 1 and 3.
The life cycle of an IC consists of three stages namely the manufacturer, issuer and user stages.
During the manufacturer stage access to the memory of the IC is provided by special physical access controls as well as access protection on the IC itself. The access controls are typically realized by probing special contacts directly on the circuit. The IC serial number 30 and the manufacturers code 26 are programmed into the IC. The secret transport code 20 is also programmed into the IC. This code is not readable from outside the IC after this stage. The secret transport code is used to identify a specific issuer. The secret transport code is protected by the electronic circuits of the IC.
While in the issuer stage, application specific information is programmed into the IC. Application specific information relates to the specific application that the IC will be used for, for example a specific type of vending machine. To activate the programming the correct corresponding secret transport code must be presented by the issuer to the IC. The presented transport code is compared with the stored transport code 20 using a compare function 54. Access to the memory area 12 of the IC is protected by a control access function 56.
If the correct transport code is presented to the IC then the memory area of the card can be accessed. This permits the application or utility area 36 to be programmed. The information programmed into this area may be diverse and for example may relate to a terminal with which the IC can be used, restrict the application of the IC in a particular way, or contain any other required information.
The token counter value 34 is also programmed into the area 32. The number of tokens depends on the application of the IC.
The secret derived key is calculated by the issuer using the IC serial number 30 and a secret function which is defined by the issuer, and then stored.
After the initial use of the transport code by the issuer a new secret value can be stored in place of the transport code 20 as the derived validation key 20A.
The user stage follows the issuer stage. Only limited read access to the memory is permitted. Access to the memory is not permitted by special circuitry provided on the IC. The contents of the memory can only be modified by decrementing the token counter value 34, or by writing a value to the application or utility area 36. Any other access is restricted to the reading of the contents of the memory, excluding the secret derived key 16.
Referring to the left of the serial interface in FIG. 2, the IC reader or terminal includes an IC serial number reader 58, an encoding function 60 of the issuer, a random number generator 62, storage 64 for a derived validation key or a secret derived key, a validation encryption function 66, a comparison module 68, storage for an issuer's key 70, and a command generator 72.
When the IC is presented to the terminal the IC's serial number 30 is read by the reader 58 in the open i.e. without any encoding of the IC's serial number taking place. A derived validation key or secret derived key is calculated by the terminal using the serial number, the issuer's key 70, and the encoding function 60 stored in storage 64.
Commands are issued to the IC via the module 72. Commands can consist of but are not limited to, a validation command, a token decrement command or read card serial number command. At the same time a random number 74 produced by the generator 62 is transferred to the IC.
Reference is made particularly to the situation in which the command from the module 72 is a token decrement command. The decrement command can be a coded bit string that can be decoded by the control 56 to enable the chosen action. The control 56 issues a command to a token decrement unit 76, to decrement the token count stored in the token counter 34 that forms part of the memory 10. If this function is carried out successfully, and this implies that the required number of tokens are present in the token counter 34 and checked by the control 56, the validation encoding function is implemented by the validation encoding function 52 operating on the secret derived key 16 and the challenge or random number 74. The token counter 34 decrements the token count. The response 78, produced by the validation encoding function 52 and controlled by the control 56, is supplied through the serial interface 42 to the comparison module 68. If an insufficient number of tokens are present, the IC either does not respond or responds with an invalid response 78. The other input to the comparison module 68 is the output of the encoding function 66 operating on the secret derived key 64 in the terminal and on the challenge 74.
Commands from module 72 to control 56 can consist of, but are not limited to a validation command, a token decrement command or read card serial number command. There commands are encoded and transported through the serial interface 42.
The operation of the encoding function 60 on the issuer's key and the IC serial number, which is unique to the IC reader terminal, produces a secret derived key which should be identical to the secret derived key 16 in the IC. The encoding functions 52 and 66 are identical and thus, for a valid IC, the encoded output of the function 66 should be identical to the response 78.
The token counter value on the IC is error corrected by the error correction function 40. This ensures that errors are corrected during an IC transaction to improve the reliability of token storage. For example an error may have arisen during a previous transaction in that there might have been a power failure or the IC may have been removed from the terminal before the previous transaction was completed.
The IC reader thus calculates a predicted response for the IC by using the challenge value 74 and the secret derived key in storage 64. The predicted response is compared to the IC response 78. If the two values match the IC and the transaction are accepted as valid. If no match is found the IC is rejected. If no tokens exist on the IC then the IC does not respond and the transaction is cancelled.
Information can be included in the challenge value 74. Thus the challenge value can be totally random but alternatively can be partially random with the remainder of the value being used to convey information, to the IC, for any desired purpose. This information can for example be used for token value confirmation.
On the other hand the IC which is being challenged can also replace a portion of the challenge with information or a command value before feeding it through the algorithm or encoding function 52 to generate the response 78. The device that originated the response can then do the reverse algorithm (decoding or decryption) to verify that the resultant value corresponds to part of the challenge. If it corresponds it could then accept the other part as valid information or a valid command. This mechanism can be usefully implemented with IC card systems, as well as other applications.
In one respect the operation of the system can be summarized as follows. The terminal presents a challenge to the IC by generating a random number and sending it to the IC. The IC transforms this challenge into a unique response, using an algorithm, only if the desired number of tokens is available and only after these tokens have been successfully deducted from the token counter. The response is returned to the IC reader and is correlated with a response which is predicted by the card reader. The IC and the IC reader use the secret derived number as the key to the algorithm.
If the correlation is successful the validity of the IC is proven and the token transaction is accepted.
The aforementioned mechanism is different from a design where an IC is authenticated with a challenge and response action which is not directly linked to the successful deduction of tokens.
The IC referred to hereinbefore may be provided in any suitable way and, particularly for token card use, on a plastic or similar card. Also, although the invention has been described with reference to an IC, the foregoing principles can be embodied in any appropriate circuit.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A method of operating a circuit such as an integrated circuit carried on a plastic card which includes the steps of accepting a challenge, and generating a first response to the challenge using a first algorithm which operates on at least the challenge and a secret key derived from information relating to the circuit. The challenge may be generated, and accepted, by the circuit, with a corresponding challenge being generated externally of the circuit. Alternatively, the challenge is generated externally of the circuit and is then accepted by the circuit. A token count may be stored in the circuit and the first response is generated if a decrement command is successfully carried out on the token count. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 12/486,228 filed Jun. 17, 2009 now U.S. Pat. No. 8,241,404 which is hereby incorporated by reference and is assigned to the assignee of the present invention.
BACKGROUND OF THE INVENTION
The present invention relates generally to improvements in operations of an integrated gasification combined cycle plant, and more specifically to methods of recycling supplied carbon dioxide-rich gas from syngas to a gasifier and/or a radiant syngas cooler inlet after heating.
In at least some known integrated gasification combined cycle systems (IGCC), carbon dioxide (and, more generally, carbon dioxide-rich gas) removed from syngas is vented or is used for the production of chemicals, and is typically not recycled to the gasifier (also referred to herein as gasification reactor). In those systems wherein carbon dioxide-rich gas has been recycled back to the gasifier (i.e., in some gaseous feedstock plants and a few liquid feedstock plants), the recycling has been performed to increase the carbon monoxide to hydrogen ratio in the syngas for processes generating oxo-chemicals. However, in such processes, no benefits have been achieved with regard to reduced oxygen consumption or improved carbon conversion with a gaseous feedstock.
A need exists for improving IGCC efficiency with respect to processing of carbon dioxide-rich gas in an IGCC plant. Specifically, a need exists for a gasification method that has a reduced oxygen and/or hydrogen consumption, and that has an increased carbon conversion. Additionally, it would be advantageous if cooling methods could be provided that required a lower heating value as compared to conventional methods, thereby providing for a more cost-efficient and economical alternative.
BRIEF DESCRIPTION OF THE INVENTION
It has now been discovered, surprisingly, that by recycling carbon dioxide-rich gas to a gasifier in gasifying systems such as used in an IGCC plant, the oxygen from the carbon dioxide-rich gas participates in the gasification reactions, and facilitates reducing oxygen consumption and increasing carbon conversion. Both reduced oxygen consumption and higher carbon conversion facilitate increased IGCC plant efficiency. Mixing carbon dioxide-rich gas with hot syngas at the inlet of a radiant syngas cooler as described herein, favorably alters the reverse water gas shift reaction, such that the carbon dioxide reacts endothermically with hydrogen in the syngas to facilitate producing more carbon monoxide. Increased carbon monoxide facilitates reduced hydrogen consumption, and increased IGCC efficiency.
In a first aspect, a method of recycling from a first syngas mixture of a gasification system is provided. The method includes removing carbon dioxide-rich gas from the first syngas mixture in a separation device; compressing the carbon dioxide-rich gas; and feeding at least a first portion of the compressed carbon dioxide-rich gas to a gasifier.
In another aspect, a method of recycling carbon dioxide from a first syngas mixture of a gasification system is provided. The method includes removing carbon dioxide-rich gas from the first syngas mixture in a separation device; compressing the carbon dioxide-rich gas; producing a second syngas mixture in a gasifier; mixing the second syngas mixture and at least a first portion of the compressed carbon dioxide-rich gas to form a combined syngas mixture; and introducing the combined syngas mixture into a radiant syngas cooler to facilitate cooling the second syngas mixture.
In a further aspect, a method of recycling carbon dioxide from a first syngas mixture of a gasification system is provided. The method includes removing carbon dioxide-rich gas from the first syngas mixture in a separation device; compressing the carbon dioxide-rich gas; producing a second syngas mixture in a gasifier; mixing the second syngas mixture and at least a first portion of the compressed carbon dioxide-rich gas to form a combined syngas mixture and introducing the combined syngas mixture into a convective syngas cooler to facilitate cooling the second syngas mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an exemplary integrated gasification combined-cycle (IGCC) power generation plant; and
FIG. 2 is a schematic drawing that illustrates exemplary processes of the invention wherein carbon dioxide-rich gas, from the syngas in the separation unit, is recycled to one of the gasifier, radiant syngas cooler, and convective syngas cooler.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic diagram of an exemplary integrated gasification combined-cycle (IGCC) power generation plant 100 . FIG. 2 is a schematic diagram illustrating exemplary processes of the invention. While FIG. 1 depicts only a portion of IGCC plant 100 , it should be understood by one skilled in the art that the methods as described herein can be used in a complete IGCC plant (including at least one steam turbine engine and an electrical generator) and/or in structurally similar IGCC plants as known in the art.
Furthermore, it should be understood by one skilled in the art that while described herein with an IGCC power generation plant, the present invention can be used with any known separation and/or gasification system without departing from the scope of the present invention. More particularly, systems including separation devices for providing physical and/or chemical separation, pressure-swing adsorption, temperature-swing adsorption, membrane separation, and the like, and combinations thereof can suitably be used with the methods of the present invention.
In the exemplary embodiment, IGCC plant 100 includes gasification system 200 . Moreover, in the exemplary embodiment, system 200 includes at least one air separation unit 202 that is coupled in flow communication with an air source (not shown) via an air conduit 204 . Such air sources may include, but are not limited to, dedicated air compressors and/or compressed air storage units (neither shown). Unit 202 separates air into oxygen (O 2 ), nitrogen (N 2 ), and other components are released via a vent (not shown).
System 200 includes a gasifier 208 that is coupled in flow communication with unit 202 and that receives the O 2 channeled from unit 202 via an O 2 conduit 210 . System 200 also includes a coal grinding and slurrying unit 211 . Unit 211 is coupled in flow communication with a coal source and a water source (neither shown) via a coal supply conduit 212 and a water supply conduit 213 , respectively. Unit 211 is configured to mix the coal and water to form a coal slurry reactant stream, referred to hereinafter as “feedstock” (not shown) that is channeled to reactor 208 via a coal slurry conduit 214 .
Gasifier 208 receives the feedstock and O 2 via conduits 214 and 210 , respectively. Gasifier 208 facilitates the production of a hot, raw synthetic gas (syngas) stream (not shown). The raw syngas includes carbon monoxide (CO), hydrogen (H 2 ), carbon dioxide (CO 2 ), carbonyl sulfide (COS), and hydrogen sulfide (H 2 S). While CO 2 , COS, and H 2 S are typically collectively referred to as acid gases, or acid gas components of the raw syngas, from hereon, CO 2 will be discussed separately from the remaining acid gas components. Moreover, gasifier 208 also produces a hot slag stream (not shown) as a by-product of the syngas production. The slag stream is channeled to a slag handling unit 215 via a hot slag conduit 216 . Unit 215 quenches and breaks up the slag into small slag pieces wherein a slag removal stream is produced and channeled through conduit 217 .
Referring to FIG. 1 , gasifier 208 is coupled in flow communication with radiant syngas cooler (RSC) 144 via a hot syngas conduit 218 . RSC 144 receives the hot, raw syngas stream and transfers at least a portion of the heat to heat recovery steam generator (HRSG) 142 via conduit 146 . Subsequently, RSC 144 produces a cooled raw syngas stream (not shown) that is channeled to convective syngas cooler (CSC) 260 via a syngas conduit 219 . CSC 260 further cools the raw syngas stream.
Referring again to both FIGS. 1 and 2 , the cooled raw syngas stream is then channeled to a syngas scrubber (shown in FIG. 2 generally at 270 ) and low temperature gas cooling (LTGC) unit 221 via a syngas conduit 220 . Unit 221 removes particulate matter entrained within the raw syngas stream and facilitates the removal of the removed matter via a fly ash conduit 222 . Unit 221 also provides additional cooling to the raw syngas stream. Moreover, unit 221 converts at least a portion of COS in the raw syngas stream to H 2 S and CO 2 via hydrolysis.
System 200 also includes a separation device 250 that is coupled in flow communication with unit 221 and that receives the cooled raw syngas stream via a raw syngas conduit 225 . Device 250 facilitates removing at least a portion of acid components (not shown) from the raw syngas stream as discussed in more detail below. Such acid gas components include, but are not limited to, CO 2 , COS, and H 2 S. Moreover, in one aspect, device 250 is coupled in flow communication with a sulfur reduction subsystem 275 via a conduit 223 . Subsystem 275 also receives and facilitates the separation of at least some of the acid gas components into components that include, but are not limited to, CO 2 , COS, and H 2 S. The separation and removal of such CO 2 , COS, and H 2 S via device 250 and subsystem 275 facilitates the production of a clean syngas stream (not shown) that is channeled to gas turbine 114 via a clean syngas conduit 228 .
Referring to both FIGS. 1 and 2 , device 250 channels a CO 2 -rich gas stream to gasifier 208 via a CO 2 -rich gas stream conduit 224 . As used herein, “carbon dioxide-rich gas” or “CO 2 -rich gas” refers to a gas stream having over 50% (by weight) carbon dioxide. In one aspect, a final integrated acid-rich gas stream (not shown) includes the CO 2 -rich gas stream and also includes predetermined concentrations of COS, and H 2 S (not shown), which have been further separated from the raw sygas stream by sulfur reduction subsystem 275 as described above, and optionally, tail gas treatment unit (TGU) 277 . In some embodiments, as shown in FIG. 2 , after separating COS and H 2 S, the stream containing COS and H 2 S is compressed via compressor 300 prior to being mixed with the CO 2 -rich gas stream and channeled to gasifier 208 via CO 2 -rich gas stream conduit 224 .
Separation device 250 removes from about 15% (by total moles carbon dioxide present in syngas) to about 50% (by total moles carbon dioxide present in syngas) carbon dioxide-rich gas from the syngas. As noted above, the CO 2 is channeled as CO 2 -rich gas stream (also referred to herein as “recycled CO 2 -rich gas stream”) or with COS and H 2 S as final integrated acid-rich gas stream to gasifier 208 .
Separation device 250 is coupled in flow communication with gasifier 208 via conduit 224 wherein the recycled CO 2 -rich gas stream is channeled in predetermined portions to gasifier 208 . As further shown in FIG. 2 , CO 2 -rich gas from device 250 is compressed via CO 2 compressor 302 and is heated via CO 2 heater 304 when channeled via conduit 224 .
In operation, in one embodiment, O 2 and feedstock, via conduits 210 and 214 , respectively, maybe mixed with CO 2 -rich gas, via conduits 224 and 402 , that has been compressed in compressor 302 and that may or may not have been heated in heater 304 . The resulting feedstock mixture is fed to inlets 306 a , 306 b , and 306 c of gasifier 208 , wherein gasification occurs, in accordance with conventional procedures, to produce syngas.
It has been found that by compressing and/or heating the CO 2 -rich gas prior to feeding a portion into a gasifier, an increased carbon conversion during gasification in gasification system 200 and subsequent processes in IGCC plant 100 is facilitated. In one embodiment, the methods of the present invention can increase carbon conversion by up to about 3% as compared to conventional gasification systems. The increased carbon conversion facilitates improving the efficiency of IGCC plant 100 . More particularly, by increasing the carbon conversion in gasifier 208 , an increased concentration of carbon monoxide (CO) is produced via the Boudouard reaction:
CO 2 +C→2CO
and the reverse water gas shift reaction:
CO 2 +H 2 →CO+H 2 O
By increasing carbon monoxide production, a reduced oxygen consumption during gasification is facilitated, which further facilitates increasing IGCC plant 100 efficiency. Specifically, when the CO 2 -rich gas is compressed, less oxygen is required during gasification as CO produced in the Boudouard and reverse water gas shift reactions provides an oxygen source. In one embodiment, the methods of the present invention can reduce oxygen consumption by up to about 2% per unit of syngas production (i.e., hydrogen and CO production) as compared to conventional gasification systems.
The CO 2 -rich gas separated from the syngas mixture in a separation device 250 is typically compressed to a pressure in the range of from about 50 pounds per square inch to about 300 pounds per square inch above the pressure in gasifier 208 of a conventional IGCC plant 100 . The gasifier pressure typically ranges from about 400 pounds per square inch to about 900 pounds per square inch.
In another aspect, if the CO 2 -rich gas is heated, less O 2 is required during gasification to heat the syngas. Specifically, heated CO 2 -rich gas is already being added to the syngas, and thus the temperature need not be raised to the extent of conventional gasification to produce the desired hot raw syngas. As such, a more efficient IGCC gasification process is facilitated.
Compressed CO 2 -rich gas typically has a temperature ranging from about 200° F. (93.3° C.) to about 300° F. (148.9° C.). When heated, the compressed CO 2 -rich gas is typically heated to a temperature of from about 550° F. (278.8° C.) to about 700° F. (371.1° C.). For example, in one aspect, the compressed CO 2 -rich gas is heated to a temperature of about 650° F. (343.3° C.).
In addition to reduced oxygen consumption, a higher carbon conversion (produced when CO 2 -rich gas is compressed and/or heated) can lead to a reduced hydrogen consumption via the reverse water gas shift reaction described above. In particular, CO has a lower heating value as compared to H 2 . Accordingly, by substituting CO for H 2 in the gasification process, improved efficiency results.
Syngas produced in gasifier 208 exits the gasifier 208 at outlet 310 . As described generally above, the hot raw syngas is channeled to RSC 144 and CSC 260 wherein the syngas is cooled and is then channeled to syngas scrubber 270 , LTGC unit 221 and, finally, to separation device 250 .
In one aspect, the hot raw syngas may be cooled prior to being introduced into RSC 144 by mixing the hot raw syngas mixture at addition point 312 with a portion of compressed and/or heated carbon dioxide-rich gas separated by separation device 250 via conduit 404 to form a combined syngas mixture. The combined syngas mixture may then be introduced into RSC 144 via inlet 314 where it is cooled.
It has been found that by mixing the hot raw syngas produced in gasifier 208 with a portion of compressed and/or heated CO 2 -rich gas, IGCC plant 100 can further be run more efficiently. Specifically, as described above, the compressed and/or heated CO 2 -rich gas increases carbon conversion via the reverse water gas shift reaction, thereby reducing the hydrogen consumption. Because CO has a lower heating value as compared to H 2 , CO is also capable of being cooled more efficiently as compared to H 2 , thus resulting in a lower cost and higher efficiency IGCC plant 100 .
Additionally, in some plants, the separation systems further include soot blowing in radiant syngas cooler 144 to blow off deposits of ash and slag on the tubes of cooler 144 . Conventionally, nitrogen (N 2 ) is used for the soot blowing. With the present methods, however, CO 2 can be used in place of N 2 for soot blowing to provide further advantages. Specifically, as CO 2 is denser than N 2 , less CO 2 is required for soot blowing. Furthermore, it has been found that CO 2 is easier to separate from the syngas as compared to N 2 .
Cooled syngas exits RSC 144 at outlet 318 and may be channeled to CSC 260 for further cooling. Particularly, in one embodiment, the syngas is further cooled to a temperature of about 900° F. (482.2° C.) to about 1600° F. (871.1° C.), and more particularly, to a temperature of about 1300° F. (704.4° C.). Once cooled, the syngas may be introduced into syngas scrubber 270 and LTGC unit 221 for removal of particulate matter entrained within the raw syngas stream and then introduced into separation device 250 to facilitate separation of at least some of the acid gas components into components that include, but are not limited to, CO 2 , COS, and H 2 S.
In one aspect, the cooled syngas exits RSC 144 and is mixed at addition point 320 with a portion of compressed carbon dioxide-rich gas, separated by separation device 250 to form a combined syngas mixture. Typically, if compressed CO 2 -rich gas is added at addition point 320 , the CO 2 -rich gas is not heated in CO 2 heater 304 . As the compressed CO 2 -rich gas is not heated, it can allow for further cooling of the cooled syngas.
Once mixed, the combined syngas mixture is fed to inlet 322 of convective syngas cooler (CSC) 260 where it is subjected to further cooling. Cooled syngas exiting the CSC 260 at outlet 326 is typically at a temperature in the region of from about 400° F. (204.4° C.) to about 800° F. (426.7° C.). The cooled syngas is then fed to syngas scrubber 270 , LTGC unit 221 and separation device 250 .
While described herein as conducting consecutive addition points of compressed and/or heated CO 2 -rich gas into the syngas mixtures of gasification system 200 , it should be recognized that the compressed CO 2 -rich gas may be added at only one or two of the addition points described above without departing from the scope of the present invention. For example, in one aspect, syngas is first produced with only O 2 and feedstock in gasifier 208 (i.e., without the addition of compressed and/or heated CO 2 -rich gas) and the syngas mixture can then be mixed with a first portion of compressed and/or heated CO 2 -rich gas at addition point 312 and cooled in RSC 144 . In another aspect, syngas is produced from O 2 and feedstock and cooled in RSC 144 . Once the cooled syngas exits RSC 144 at outlet 318 , the cooled syngas can be mixed with a first portion of compressed and/or heated CO 2 -rich gas at addition point 320 and further cooled in CSC 260 .
One additional advantage of using the methods of the present invention includes not requiring the inclusion of sulfur removal subsystem 275 in IGCC plant 100 . In particular, as the compressed and/or heated carbon dioxide-rich gas is removed from separation device 250 and mixed again with syngas, the CO 2 -rich gas does not have to be purified to remove sulfur. As a result, separation device 250 can be optimized to allow the CO 2 -rich gas to contain sulfur.
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. | Method of producing syngas in an IGCC system, comprising compressing and heating carbon dioxide-rich gas to produce heated compressed carbon dioxide-rich gas, mixing the heated compressed carbon dioxide-rich gas with oxygen and feedstock to form a feedstock mixture, subjecting the feedstock mixture to gasification to produce syngas, cooling the syngas in a radiant syngas cooler, contacting syngas cooled in the radiant syngas cooler with compressed carbon dioxide-rich gas to further cool the syngas, and removing an amount of carbon dioxide-rich gas from the product mixture and compressing the removed carbon dioxide-rich gas prior to mixing with oxygen and feedstock. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a glazing, especially for windows and French windows, of the type consisting of two panes located opposite one another and retained by means of a rigid frame provided with leakproofing means.
More specifically, the invention relates to a glazing of the type indicated, which is provided with a deformable and leakproof member for equalizing pressure between the outside and the inside, this word designating, here, the space contained between the two panes.
The pressure variations between the outside and inside of a double glazing can be attributed to meteorological phenomena or to heating of the gas contained inside under the effect of the sun. To prevent them from causing damage, it is customary to give the panes sufficient thickness and embed them firmly in the frame. It should be noted that the larger the glazing, the more the frame is subjected to stress: if the dimensions of a square glazing are doubled, the forces attributed to the differences in pressure are quadrupled, whilst the length of the frame is merely doubled.
There has been a proposal (U.S. Pat. No. 2,207,745) to equalize the pressures by means of holes provided, if aporopriate, with filters, but this solution is not entirely effective in eliminating the condensation arising from moisture inside the glazing.
There has also been a proposal (DE-A No. 2,730,119) to place between the panes and the frame an element made of deformable material, such as rubber. This element constitutes the leakproofing means anchoring the panes to the frame, and between the panes it forms a flexible diaphragm, one face of which is in contact with the outside air and the other face in contact with the inside of the glazing and which is deformed under the effect of the relative pressure variations. The disadvantage of this solution is that it gives rise to forces exerted on the part of the element forming the leakproofing means, with the attendant risks of fatigue or displacement.
The document U.S. Pat. No. 4,065,894 describes a glazing, the frame of which, preferably made of wood, contains in its thickness a receptacle which communicates with the outside via a duct.
Located within this receptacle is a bladder or vessel made of flexible material, the interior of which is connected to the inside of the glazing by means of a tube. This tube passes through a gasket made of elastomeric material, which serves both to provide leakproofing between the frame and the inside of the glazing and to prevent the panes from moving closer to one another. The frame has a groove in which the edges of the panes and the elastomer gasket are accommodated, the edges of this groove preventing the panes from moving apart.
This device makes it possible to achieve effective equalization of the pressures inside and outside, but it makes it necessary to provide a bulky frame. In fact, on the one hand, the frame must be large enough to contain the cavity in which the bladder is located, and this cavity must allow variations in volume of the bladder; these variations in volume increase if the distance between the panes increases. On the other hand, since the panes are retained by means of a groove, the frame necessarily has a width greater than the distance between the outer faces of the panes. For these two reasons, it becomes necessary to limit the distance between the panes, but this reduces the heat-insulation qualities of the glazing.
There has, moreover, been a proposal for arrangements in which the panes of a glazing are bonded to a "spacer" section located between them (FR-A No. 1,433,252), the glazing being without any pressure-equalizing member. It seems possible, by using this technique, to reduce the forces exerted on the frame which are attributed to internal excess pressure and therefore to reduce its thickness, but there has never been a proposal to locate such glazing other than within grooves provided within the frame. This system would therefore make it possible, in theory, to increase the distance between the panes for a given thickness of the frame, but the latter nevertheless still has a thickness greater than the distance between the outer faces of the panes. On the other hand, this system scarcely makes the process of obtaining and installing the glazing any simpler.
Furthermore, it is conventional to fasten to the frames various accessories enabling the glazing to interact with a fixed surround, for example hinges, bearings, leakproofing means and lock components. This has been done for a very long time with wooden frames and single panes, and the technique has simply been modernized for glazing with multiple planes and metallic or like frames, having a shape which allows various accessories to be attached.
The end result of this is a costly construction, because it involves several stages, some carried out at the factory and others on site.
The object of the invention is to provide a glazing which, at the same time, has a higher quality than those of the prior art in terms of its heat-insulation properties, because of an increased distance between the panes, and is simpler to obtain and has a reduced cost price.
The object of the invention is also to provide a simple process for obtaining such a glazing.
BRIEF DESCRIPTION OF THE INVENTION
The invention thus provides a glazing consisting of two panes located opposite one another and retained by means of a rigid frame provided with leakproofing means, this frame being provided with at least one deformable and leakproof member for equalizing pressure between the outside and inside of the glazing, this member being independent of the said leakproofing means, the particular feature of the glazing being that:
The frame consists of sections which bear on the inner faces of the panes and which are fastened to these by means of an anchor which prevents the panes from moving apart from each other.
the pressure-equalizing member is located inside the glazing in relation to the said sections,
the sections have, towards the outside of the glazing, a shape allowing direct attachment of accessories enabling the glazing to interact with a fixed surround.
Anchor refers, here, to a non-mechanical means ensuring that the pane is fastened permanently to the section, for example, bonding. The anchor can also perform a leakproofing function, but it can be advantageous to provide an additional leakproofing means, for example made of a material having high leakproofing in respect of water vapor.
The combination of the elements which have just been mentioned provides the following advantages:
The fact that the sections constituting the frame are anchored to the inner face of the panes makes it possible to move the panes apart until their outer faces are in the planes defining the limits of the overall dimensions of the glazing; in other words, the distance between the panes is the maximum possible for a total glazing thickness which is otherwise fixed.
This results in a considerable increase in the volume of the inner space and therefore the possibilities of heat and sound insulation of the glazing, as a result of the fitting of interpolated elements.
The fact that the pressure-equalizing member is located inside the glazing makes it possible to install it at the factory, whilst avoiding the problems of mechanical protection of this member during transport and during the fastening of various accessories. It also makes it possible to reduce the weight and simplify the sections of the frame.
The fact that the same section combines the "spacer" functions with that of supporting the accessories results in a substantial simplification of construction and a lowering of the cost. It is possible, in fact, to produce the "self-supoorting" glazing, together with its accessories, directly at the factory, the work on site being confined to installing it in its surround.
As has been seen, this result can be achieved only as a result of the interaction of the various elements of the invention.
According to a preferred method of production, the sections constituting the frame are contained completely in the gap defined by the planes of the outer faces of the panes.
Preferably, a means for protecting the pressure-equalizing member against radiation penetrating through the panes is provided, this protection means dividing the inner space of the glazing into two communication chambers which are subjected to the same pressure and one of which is peripheral and contains the said equalizing member. This protection means delimits the periphery of the glazing and the part of the latter which is transparent to light. Its main use is to lengthen the useful life of the pressure-equalizing member. This member is constantly stressed mechanically during the lifetime of the glazing, and it is necessary to prevent the action of solar radiation from reducing its flexibility and leakproofing. The protection means also has an aesthetic use, since it conceals the protection means from sight.
Advantageously, the said protection means consists of at least one auxiliary section which is supported, with play, by two wings of a frame section and which, if appropriate, carries additional devices located inside the glazing.
According to another very advantageous method, the peripheral chamber contains, in addition to the equalizing member, a filler consisting of a dehydrating substance, and near the said filler of dehydrating substance there is in one section at least one orifice provided with a means of leakproof sealing, which can be removed in order to renew the said filler.
The said protective section thus ensures, in addition to the protection of the pressure-equalizing member, the concealment of the dehydrating filler and, if appropriate, its retention. It is clear that this filler must be arranged so as not to impair the function of the equalizing member. It will be noted, in this respect, that the quantity of water vapor penetrating into a double glazing depends essentially on the length of the gaskets and not on the volume between the panes. Consequently, when the distance between the panes increases, there is no change in the quantity of dehydrating substance. The filler can therefore be arranged so as to mask a smaller part of the glazed surface.
On the other hand, since the filler is renewed by a means independent of the pressure-equalizing member, there is no risk that the latter will be damaged during the operation.
Another advantage of the arrangement described is that it is possible to ensure that bearing boxes or other accessories enabling the glazing to interact with a fixed surround and carried by a section penetrate into the said chamber, but without impairing its leakproofing relative to the outside.
This method becomes possible both because of the greater distance between the panes, which exceeds the thickness of a bearing box, and because the frame sections combine the "spacer" function with the function of supporting the accessories. It will be noted that, to ensure good leakproofing, the bearing boxes and similar accessories will advantageously be installed at the factory.
The invention also provides a process for producing a glazing such as that which has just been defined.
This process is of the type according to which the sections are joined by bonding to one another and to the two panes, thus forming a leakproof assembly, its particular features being that the sections are provided beforehand with the pressure-equalizing member or members, and after bonding a pressure difference is produced between the two faces of the equalizing member or members by means of a sealable orifice provided in one section and communicating with the interior of the glazing, this pressure difference being so calculated that the average shape of said equalizing member or members during use will be intermediate between its extreme shapes, and communication between the interior of the glazing and the outside is sealed off at least up to the moment when the glazing is used.
The simplest, but not the only way of carrying out the process is as follows: after bonding and installation of the dehydrating filler, a sealing-off device, for example that intended for the renewal of this filler, is removed or is not installed. The interior of the glazing is then in communication with the surrounding atmosphere which is advantageously a dry gas, such as nitrogen. The interior of the equalizing member is then brought to a different pressure which is calculated in a way described above. For this purpose, the duct intended for connecting the equalizing member to the atmosphere during its operation is connected to a suitable pressure source, for example a gas bottle, by means of a duct provided with a temporary sealing-off means. Subsequently, this sealing-off means is closed, as is the sealing-off device mentioned above. The two faces of the equalizing member are thus made independent of the atmosphere. At the time of installation at the place of use, for example, in the hills, it is sufficient to open or remove the temporary sealing-off means.
BRIEF DESCRIPTION OF THE FIGURES
The invention will now be described in more detail by means of practical examples given in a non-limiting way and illustrated in the drawings of which:
FIG. 1 is a cross-section of one edge of a glazing according to the invention, showing the equalizing member in the case of an internal excess pressure;
FIG. 2 is a section similar to that of FIG. 1, but in the case of an external excess pressure;
FIG. 3 is a section similar to that of FIG. 1, but at the level of the dehydrating material;
FIG. 4 is a vertical section of the lower edge of a glazing provided with accessories for use as a slicing panel or a screen;
FIG. 5 is a vertical section of the top of a glazing showing a screen folded up;
FIG. 6 is a horizontal section of the edge of a glazing provided with accessories for use as a casement window;
FIG. 7 is a section through the edge of another embodiment of the glazing according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In all the Figures, the same reference symbols denote similar articles. The glazing which is the subject of FIG. 1 is formed from two rectangular and identical panes 1 which are connected at their edges by frame sections 2 all having substantially the same structure.
Each frame section 2 is composed of two identical aluminum sections 3 arranged symmetrically and connected by a central core 4 made of resin and having low thermal and sound conductivity, this structure avoiding the appearance of a thermal bridge. By "aluminum" is meant, of course, a suitable aluminum alloy, the composition of which can vary according to the circumstances of use. Other metals can, of course, be used. It would be possible, naturally, to design the frame section 2 in one piece of a material which has suitable mechanical and heat and sound insulation properties.
Each aluminum section 3 has a dovetail groove 5 for anchoring the core 4, the latter being installed by casting.
In the vicinity of the core 4, the aluminum sections 3 possess, in an opposite direction to the panes 1 and in an opposite direction to the core 4, grooves 6, 7 which are intended for the attachment of accessories which are to interact, for example with fixed woodwork, such as a window or door casing.
The total width of the frame section 2 is substantially equal to the distance between the outer faces 8 of the panes 1.
The aluminum sections 3 each have a wing 9 which projects between the panes 1 and which gives the cross-section of the frame section 2 a general U-shaped form. The panes 1 are fastened via their edge to the frame section by means of a gasket 10 which is made of extruded silicone and which provides a flexible anchor and a first leakproofing barrier in respect of water vapor. Furthermore, a strip 11 made of hot-extruded butyl is interposed and clamped between each wing 9 and the inner face of the corresponding pane 1, so as to form a second barrier against water vapor.
The end of each wing has a groove 12 on its face turned inwards. A projection 13 of an auxiliary section 14 made of polyvinyl chloride penetrates into each of these grooves. It is important to note that the projections 13 penetrate into each groove 12 with a considerable play both in a parallel direction and in a direction perpendicular to the panes. This auxiliary section is never perfectly plane because of the temperature differences between its faces. Furthermore, its length is a little less than that of the section 2, to allow for the difference between the coefficients of expansion. For these reasons, the connection between the frame section 2 and the auxiliary section 14 is never leakproof.
The auxiliary section 14 divides the inner space defined by the panes 1 and the sections 2 into a peripheral chamber 15 and a central chamber 16 (FIG. 2). These two chambers are always in communication for the reasons which have just been explained.
The auxiliary section 14 carries, on its face opposite the frame section 2, two wings 17 of right-angled cross-section, the ends of which are narrowed and brought close to one another. In FIG. 1, these two wings 17 retain between them a stretched anti-convection film 18 made of clear or tinted transparent material. In FIG. 2, the two wings 17 are not used, whereas in FIG. 3 they retain a third pane 19.
The core 4 of the section 2 is perforated with a hole 20 in which is fastened in a leakproof manner a pocket 21 in the form of a bellows, which is made of butyl with a thickness of 0.3 to 1.5 mm and which is shown in FIG. 1 substantially in its position of least volume and in FIG. 2 in its position of greatest volume, this pocket constituting the pressure-equalizing member. The interior of the pocket 21 communicates with the outside atmosphere via the hole 20, whilst its outer face is subjected to the pressure prevailing in the chambers 15 and 16, that is to say to the pressure inside the glazing.
The situation shown in FIG. 1 thus corresponds to an internal excess pressure, or more exactly to conditions which would lead to excess pressure in the absence of any pressure-equalizing member. As shown in the figures, the frame section 2 and the auxiliary section delimit the space in which this member can take effect, and at the same time they prevent solar or suchlike radiation, which would have passed through the panes, from being able to reach the pocket 21.
FIG. 3 shows the chamber 15 occupied not by the pocket 21, as in FIGS. 1 and 2, but by a mass 22 of dehydrating material consisting here, of a molecular sieve in the form of granules.
Of course, transverse partitions (not shown) prevent this dehydrating material from coming up against the pocket 21 and preventing it from functioning freely. A hole 23 passes through the core 4 of the section. This hole is threaded and is sealed off by a leakproof screw plug 24. The removal of the plug 24 and extraction of the mass 22 by means of suction or drawing off are normally carried out only when this mass is spent and must be changed, that is to say after a period of time which, here, is of the order of ten years.
FIG. 4 shows the position of accessories enabling the glazing according to the invention to be used as sliding glazing. Only the core 4 of the frame section is modified in comparison with the preceding Figures. In fact, this core 4 incorporates elongated notches 25 in which boxes 26 provided with bearings 27 are mounted. Each box 26 is closed and leakproof except on the side facing outwards, via which the bearings 27 project so as to roll on a bearing race 28 which is part of a fixed surround 29. The box 26 possesses wings 30 which bear on the ends of the frame section 2. The bottom 31 of the box comes near to the auxiliary section 14 to such an extent that practically the entire extent of the peripheral chamber 15 in the direction of the center of the glazing is used. The connection between the box 26 and the core 4 of the frame section, at the level of the notch 25, is leakproof. In an alternative form, it is possible for the box 26 carrying the bearings to be removable and for it to be surrounded in the peripheral chamber 15, by a second box 32 which is leakproof and which is connected to the core 4 in a leakproof manner. The second box 32 is shown by dashes in FIG. 4. It can be thinner than the box 26 because it does not experience mechanical forces. This alternative form is a little more complicated, but it allows the bearings to be replaced and adjusted easily. It will be noted that either of these arrangements becomes possible, without difficulty, because of the great distance between the panes. Thus, the transparent surface of the glazing extends practically up to the top of the box 26.
FIG. 4 also shows leakproofing brushes 33 mounted in the grooves 7 of the frame section 2. These brushes are the only elements which project beyond the plane of the outer faces 8 of the panes 1. They ensure leakproofing in respect of drafts, as is well known, and protect the panes 1 from contact with the fixed surround 29.
The same FIG. 4 shows the lower part of a foldable screen 34 which acts as a sun shield and is preferably reflecting. The large spacing between the panes makes it possible to give the screen 34 a structure which, in cross-section and when it is unfolded, shows a series of superimposed honeycombs.
The screen 34 is stretched downwards by means of a section 35 which, in FIG. 4, rests on the wings 17 of the section 14. The vertical edges of the screen 34 are guided by the wings 17 of the section 14 located on the sides of the glazing.
FIG. 5 shows the upper edge of a glazing equipped with the same screen 34 which, this time, is shown in the folded up state. This time, the peripheral chamber 15 is used for accommodating a pulley 36 driving cables for raising and lowering the screen.
The core 4 is notched to leave the space required for the pulley 36, but the notch is not a through-notch, so as to maintain leakproofing. To reduce the bulk of the screen 34 when it is folded up, the auxiliary section 14 is reversed, its wings 17 being on the inside of the peripheral chamber 15. These wings are cut away at the level of the pulley 36 to leave room for the latter. Moreover, the auxiliary section 14 carries the means 37 for attaching the screen 34.
The shaft 38 of the pulley 36 is supported by the aluminum sections 9 of the frame section, without interrupting the leakproofing.
In the alternative form illustrated in FIG. 5, the shaft 38 passes through one of the sections 9 so as to be connected to external drive means (not shown) by means of a leakproof gasket consisting of a widened portion of the silicone gasket 10. In another alternative form (not shown) which is more costly, but more reliable as regards leakproofing, the large width of the chamber 15 is utilized to accommodate in it a miniature drive motor, the supply cables of which pass through the frame section 2 via a leakproof gasket.
FIG. 6 shows how the grooves 6, 7 of the frame section 2 are used for retaining accessories enabling the glazing to be used as a swing door. On one side, a flexible outer leakproofing gasket 39 is anchored directly in the grooves 6 and 7 and bears on the fixed surround 40. On the other side, an additional section or swing section 41 is fastened in a groove 6 and carries an assembly gasket, or key gasket 42, which bears on the edge of the corresponding pane 1, and an inner leakproofing gasket 43 which bears on the fixed surround 40.
Dashes represent the hinge 44 which is screwed at 45 to the additional section and which is locked at 46 in the groove 7 of the frame section 2.
FIG. 6 also shows how the wings 17 of the auxiliary section 14 serve for guiding the screen 34 when it is unfolded. It is quite clear that the accessories shown in this Figure could have been fitted at the same time as an anti-convection screen, such as that shown in FIG. 1, or an additional pane, such as that shown in FIG. 3. It will be noted that the chamber 15, which is shown empty in FIG. 6, can contain a pressure-equalizing member or a dehydrating material or other accessories fastened to the core 4, and in fact the latter remains accessible without the removal or, if appropriate, with the removal of a single gasket 39, this being relatively easy.
FIG. 7 shows another embodiment of the glazing according to the invention. Here, the thickness of the glazing is appreciably greater than in the preceding Figures because of a slightly different shape of the aluminum sections 3 and the auxiliary section 14, the other elements remaining the same. This has made it possible to accommodate a more voluminous pressure-equalizing member and to provide several additional panes 19a, 19b and 19c. It is also possible to provide several anti-convection screens, such as the screen 18. There are means, such as holes (not shown) in the section 14, to equalize the pressures in the compartments delimited by the additional panes or additional screens. It is likewise possible to provide several foldable screens, such as the screen 34, or combine several of these elements. The pressure-equalizing member 21 has increased dimensions and a modified form.
The glazing of FIG. 7 is shown directly associated with elements 47, 48 of the fabric of the building by means of a fastening piece 49, which interacts with a groove 6 and gaskets 50 bearing on the panes 1.
It is to be understood that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the present invention. The preferred embodiments are therefore to be considered illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing descriptions and all changes or variations which fall within the meaning and range of the claims are therefore intended to be embraced therein. | A glazing consisting of two panes located opposite one another and retained by a rigid frame provided with leakproofing means and consisting of sections which bear on the inner faces of the panes and which are fastened to these by means of an anchor preventing the panes from moving apart, this frame being provided with at least one deformable and leakproof member for equalizing pressure between the outside and inside of the glazing, this member being independent of the said leakproofing means and being located on the inside of the glazing in relation to the said sections, and the said sections having, towards the outside of the glazing, a shape which allows direct attachment of accessories enabling the glazing to interact with a fixed surround.
This glazing provides a considerable increase in the internal volume and therefore the possibilities of heat and sound insulation, as a result of the fitting of interpolated elements. Furthermore, it can be produced completely at the factory, ready to be installed in its surround. | 4 |
[0001] This application is a continuation-in-part of copending U.S. patent application Ser. No. 09/347,700 filed Jul. 3, 1999.
BACKGROUND OF THE INVENTION
[0002] The present application relates to a deployable onboard oil containment system designed to contain all marine oil spills or any marine surface spill that has flotation matter. The system of this invention is modular and can expand to surround any distance of the spill. Due to the height and depth of this system by using the improved stabilization arrangement, the wall which is part of the system will not encounter the problems of the present booms used for marine oil spill containment.
[0003] Deployment of the present containment system around an open sea spill will allow for substantially 100% recovery of the spill that has not either evaporated or sunk. Thereby allowing for the use of skimmers inside the perimeter wall, while containment of spill remains intact. The system of the present invention will also serve as the main and only line of defense necessary to protect the coastal shorelines.
[0004] In case of a spill that does not have the present on board oil containment system for deployment, or due to sever damage of the ship together with violent water wave action, any type of recovery action or restricting movement of the spill is usually prevented. Deployment of the present containment system by stretching it in front of shoreline will prevent any spill from reaching land at anytime. The present containment system will also work in rivers acting as a control dam. While allowing waters to pass beneath the system, the wall will prevent any floating matter such as oil or debris from floating down stream, thus eliminating more contamination to the waterways.
PRIOR ART
[0005] Included in the prior art are many systems for containment of bodies of water and the use of effective disposal equipment. Generally, oil containment systems in use consist of various types of booms. These booms can be divided into several different types: Non-rigid or inflatable booms. The purpose of a boom is to contain the spill and limit the mobility of the spilled material allowing for complete and rapid recovery.
[0006] Currently, oil recovery teams using the boom recovery method can only recover 15% of the oil wasted into the waterways, by using up to four layers of boom it has been documented on its recovery. Problems noted include that these booms are too short; some have intermittent spacing allowing oil to escape either over the top or between the spacing. In most cases the use of walls or skirts have had great difficulty with containment and positioning, rendering the boom mostly ineffective in containment. For massive spills there is never a sufficient and satisfactory boom to effectively surround the area.
[0007] U.S. Pat. No. 5,480,261 relates to a flotation containment system of the boom-type which is collapsible for compact storage and which includes improved heat resistance properties, making the boom able to contain a burning surface containment for long periods of time. There appears to be no provision for an upper wall and floatation stabilizing counter balance system to keep the upper and lower wall upright during deployment and containment.
[0008] U.S. Pat. No. 5,522,674 relates to a self-inflatable containment boom having a plurality of self-inflatable units with chambers connected end to end. There is no provision for an extended upper containment wall having a means for floatation stabilization by a counter balance system to keep the upper and lower wall upright during deployment and containment. This inflatable flotation system has an open cell foam material positioned in an inner space.
[0009] Deficiencies in the general floating oil barrier found in the prior art include, but are not limit to:
[0010] A) Circumstances where oil is never secure within the barrier because it does not enclose a spill, but wraps around in a U-shape and collects as much oil as the barrier will allow.
[0011] B) The floating oil barrier is not designed for on-board deployment, which delays clean up time.
[0012] C) Reliance on aircraft or ship for delivery.
[0013] D) Retarded or difficult deployment, which impedes cleanup and allows spill to worsen.
[0014] E) A barrier will not challenge swells over 1 meter.
[0015] F) The barrier allows oil to funnel through its sectional breaks.
[0016] G) A reliance of compressed bottle gas for deployment and flotation.
[0017] H) Susceptibility for combustion.
BRIEF SUMMARY OF THE INVENTION
[0018] The oil containment system of the present invention is a two part system that consists of a first part is a four meter tall clear vinyl plastic that is 40 mil in thickness, with connecting zippers and overlapping lips on each end to lengthen the wall. The plastic is clear to allow the overseeing of the containment, removal and clean up. The width of this wall starts at 200 meters and comes in sections of 200 meters. The length of the wall is modular and can connected and expanded to surround the length of any spill. This wall is designed to stand several meters above the water surface to prevent swells up to six feet riding over this wall. The wall also extends several meters below the waters surface in order to prevent the under drift of any matter that is carried by waves. Each end of the wall is connected together after surrounding the complete spill. This assures for virtually 100 percent containment of any surface spill inside its perimeter. A second part of the oil containment system of the present invention is a series of counter balances. The materials consist of freeboard that is covered with aluminum for strength. Typically, 3.5″ thick×7.5″ wide freeboard is acceptable for the counter balances.
[0019] There are four connecting parts to the counter balance.
[0020] 1) Counter balance beam 30 , which is a vertical support beam, which attaches to the wall 10 above the surface of the water. It allows for a substantially vertical plumb position of the wall.
[0021] 2) Counter balance beam 32 is a horizontal beam that is connected to counter balance 30 that lies flat on the water surface to assure the flotation the wall.
[0022] 3) Counter balance pole 34 is a 2″ wide pole that supports both counter balance beams 30 and 32 and is positioned at a 45-degree angle to assure the strength support of the counter balance system. In this manner there is a triangle formed that supports the upright positioning, strength and flotation of the wall.
[0023] 4) Attached to the right side of counter balance beam 30 is a support spacer pole 14 that prevents collapsing from side to side. This pole 14 connects to each counter balance beam to allow for continuous upright positioning.
[0024] Attached to the end of counter balance beam 32 is a counter weight 36 , which performs two principle functions. One function is to place support to the weight of the wall per square inch, thereby not permitting the wall to tip forward. In this way, the weight is determined based on the distance between each counter balance. The second function is to serve as a drag weight to allow for smoother towing and allowing the counter balance beams to remain in an upright position during the tow to position the containment system of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1: is a drawing representing the containment system of the present invention being towed into position. The wall is placed on the back of the ship on spools controlled by hydraulics for smoother movements. A is container also placed on the back of the ship for the storage of the counter balance.
[0026] [0026]FIG. 2: is a front view of the full containment wall without the counter balance system.
[0027] [0027]FIG. 3: is a front view of the containment wall section above the water, with the counter balance attached. This drawing also displays the vertical spacers connected.
[0028] [0028]FIG. 4: is a front view of the containment wall below the water surface, this also shows the weights at the bottom skirt to maintain the rigidity of the wall.
[0029] [0029]FIG. 5: is a view of the counter balance in an open position from a left side view showing the counter balance locked into position with the counter weight attached and the connector for the horizontal spacer.
[0030] FIG 6 : is a view from the right side of the counter balance fully assembled. Along the side of counter balance is the vertical spacer that extends up and outward to connect to the next counter balance.
[0031] [0031]FIG. 7: is an overhead view of the containment system of the present invention above and below the water surface with all components connected.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring to the drawing in FIG. 1: there is a depiction of a tanker that has the deployable on-board oil containment system of this invention. The tanker has struck as reef and oil is spilling out. Two lifeboats that are equipped with out board motors and a tow loop 18 to attach the cable of the wall can deploy the containment system of this invention. The two spools swing to an outward position and lowered into the water by hydraulics. The two boats facing the opposite direction will pull on radio command to ensure that tension on the wall stays rigid. Upon command the boats will either speed up or slow down. Because the wall is on a spool and is only released during radio command this allows for the boats to have less weight to tow. After about the first 20 meters the weight reverts back to the spool regardless of the distance being pulled.
[0033] With reference to FIG. 2, there is a front view of the wall 10 from top to bottom without the counter balance system attached. The numbers represent the following: 10 is the wall itself The material is a heavy weight clear plastic, 40 mil clear vinyl plastic has been found to be satisfactory, so that the clean up can be viewed while in progress. Other material can be used. The wall typically stands a total of about 4 meters in height and is modular with each section about 200 meters in length, connecting zippers 22 and overlapping edges 23 are provided on each end of the modular section. This wall can be customized to a shorter length to fit the size of any boat, and the amount of potential spill on board the boat. With this wall depth of its skirt, water has been proven to flow around and beneath the wall leaving the debris to be contained. Anchor support holes 12 are placed into the wall 10 . These walls 10 are reinforced to support the weight that is attached to keep the skirt of the wall from bending backwards, allowing for a more rigid skirt against the current. Vertical support poles 14 slide inside special made seams in the wall 10 , both above and below the water surface. The material for construction of the vertical support poles 14 can be of various material, however a satisfactory lightweight plastic is polyvinyl chloride or “PVC” plastic. This material is lightweight, flexible and in short pieces extremely strong. Typically, if each pole is 1½ meters in length and 1 inch in circumference satisfactory strength can be achieved in the support system. The support poles 14 are spaced apart along the length of the wall. It has been found that support poles 14 placed about 20 centimeters apart assure near maximum strength support to the wall 10 .
[0034] Secure wall straps 16 are made of woven fabric that can be are sown into the wall with two pieces on both sides sown together to insure maximum strength against tearing of the wall during towing. It has been found that the use of nylon as the material for constructing the wall straps is acceptable. These straps 16 have clamps that slide together and lock into place with a manual release for removal. The straps 16 are design to hold the counter balance beam 30 vertically against the wall 10 thereby not allowing any separation of the wall and counter balance system. All straps 16 are above the water surface 28 and are placed for balance support. Tow loops 18 are designed and placed at the beginning and end of each 200-meter section. They are constructed of nylon fabric sown together on both sides of the wall with a loop thereon for that attachment of the towline. The three loops are placed above the water line. This allows for a more even towing, without lifting the wall out of the water.
[0035] [0035]FIG. 3 is a front view of the containment wall 10 above the water surface 28 , with counter balance system attached. There can be seen the wall 10 , the vertical support poles 14 , secure wall straps 16 , tow loops 18 , counter balance beam 30 secured against the wall by the secure wall straps 16 to allow the wall to remain plumb. The connecting zipper 22 is shown with overlapping flap 23 that securely connects the wall sections without adding stress when being towed, made of nylon and plastic. The horizontal support spacer 24 , when not used, lies connected resting on the side of the counter balance beam 30 in a vertical position. When connected as shown in FIG. 3 is fully attached from counter balance to counter balance 30 . For stability the connecting poles 23 are used to assure that the wall does not tilt over on its side. The connecting poles 23 are put in place manually as the wall is dispensed from the onboard container.
[0036] [0036]FIG. 4 is a front view of containment wall 10 depending below the water surface 28 . The skirt of the wall 11 depending beneath the surface of the water 28 shows the anchor support holes. The vertical support poles 14 are shown inside the skirt. This allows the skirt to remain rigid, not allowing any buckling against the force of the current. The connecting zipper 22 is shown with the overlapping flap 23 . The anchor weights 26 are attached to the wall skirt below the waterline 28 to keep the lower wall skirt 11 from floating to the surface of the water. These anchor weights 26 are typically about 2 lbs. each and are space about 28 inches apart. Each weight 26 hangs below the lower wall skirt 11 below the water line 28 . It is hung with nylon cord 17 , where the water surface line is represented at 28 .
[0037] [0037]FIG. 5 represents the left side view of counter balance system assembled: Vertical counter balance beam 30 and the diagonal support beam 34 and horizontal counter balance support beam 32 assembled in operating configuration. The vertical support beam 29 is constructed of free board that is covered in aluminum. The diagonal support beam 34 must be light and strong. It has been found that a combination of aluminum tubing with a fiberglass sheet overlay is acceptable. It is understood that other materials familiar to those skilled in the art can be used as well. The counter balance beam 30 attaches to the wall 10 above the water surface 28 and each is secured to the wall 10 by the straps 16 on the wall, this allows for the wall 10 to remain plumb and not fall over against winds. Horizontal counter balance beam 32 , is connected to beam 30 , but rides on the waters surface. This allows for the flotation of the wall. Horizontal counter balance beam 32 also is made of freeboard covered in aluminum. The length of the board is conveniently about 5 feet. The horizontal counter balance beam 32 also houses counter balance pole 34 when stored.
[0038] Counter balance pole 34 is braced against both counter balance beams 30 and 32 to form a floating triangle allowing for greater strength and the full support of the wall. The counter weight 36 a weight that is attached to the end of counter balance beam 32 which allows for adequate support per square inch of wall not permitting for the wall to tip over. This arrangement with the counter weights in place keeps the assembly from tipping over, as from gust of wind. The counter weights 36 are also used as a drag to keep the counter balance assembly in the water while being towed. The horizontal support spacer clamp 38 acts as a locking clamp that keeps the horizontal spacer bar 42 in place.
[0039] [0039]FIG. 6 represents the right side view of the assembled counter balance system. Spacer guide loop 40 is used to attach the spacer guide rope 41 from counter balance to counter balance. The horizontal space bar 42 is shown in its resting position along side of the vertical beam 30 . This space bar 42 when used is manually raised up from the side of the vertical beam 30 and move upwardly to attach to the next counter balance beam 30 . When in place the horizontal space bar 42 is used to support the balance of the wall 10 . Thereby the counter balances working together do not allow the wall 10 and counter balance beams to tip over on its side. The horizontal space bar 42 locks in place to the horizontal spacer clamp 38 and is secured in place until manually removed.
[0040] In FIG. 7 can be seen as an overhead view of containment wall 10 with the counter balance system of the present invention above and below the water line 28 . The spacer control rope 44 controls the movement of counter balance beam 32 keeping the required spacing and not allowing the beams to drift together or float toward each other.
METHOD OF OPERATION
[0041] The oil containment system of the present invention can easily be deployed from a tanker or other recovery vessels. The containment system can be conveniently stored on spools that are about 15 ft tall and are operated by hydraulics for deployment. The recommended length of this system stored on board an oil carrying tanker is a square quarter mile for rapid deployment and containment. After the attempt to secure the safety of its crewmembers and stabilize the leakage, the containment system of the present invention can be deployed. Should the vessel be unable to deploy the containment system, the nearest harbor should have enough footage of the containment system to secure the coastal shorelines, by deploying the wall out along the shoreline. While a rescue and recovery vessel carrying another the containment system works its way out to secure the perimeter of the spill. The hydraulic system that operates the spool and places it into position can be secured either to the front or the back of the vessel for optimal maneuverability. The spools are placed onto the water and each section of the wall is towed in a clockwise and counter clockwise direction, by several small outboards, such as lifeboats, they circle the spill at least fifty meters away from the spill. With two trailing boats trailing to attach the counter balances. By working from the connecting points back to the spools the counter balances are placed such that the tension stays on the wall until all counter balances have been placed thereon. Thus enabling successful upright flotation of the wall.
[0042] The clean up procedure of the wall may be accomplished as follows. Once the spill has been retrieved, the wall is then reversed rolled back onto its spool. By removing the counter balance system from the closet to the spool, the spool is put into reverse mode. The wall is then taken back to dock where the clean up process begins. The removal of the oil or any matter on the wall can be washed down as the spool unwinds. The cleaning solution can be any oil cutting detergent and scrub the wall as it is reversed onto another spool. The oil or other matter is collected and removed from the area. The spool is then placed back onto the vessel and stored.
[0043] The containment system can be stored in both places, on shore or on the vessels; it rests on its spool while the counter balances are place in a stackable position in a storage container. The placement of this equipment requires either a stern or bow position for optimal maneuverability. Optimally, there are sufficient counter balances positioned on every mile stretch to keep the deployed wall floatable.
[0044] Therefore, the foregoing is considered as illustrative only of the principles of the present invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not intended to limit the invention to the exact contraction and operation shown and described, and all suitable modifications and equivalents may be resorted to and which may fall by within the scope of the present invention. | A deployable marine on-board containment system of a clear plastic wall, supported by a floatation counter balance system to allow for towing and surrounding of any marine surface spill; with rapid deployment and containment of any marine spill that consists of floating matter permitting almost total collection of any marine spill in the open sea, on a river or in a coastal shoreline area; without using chemical or any other additives thereby allowing the collected material to be recovered and reused. | 4 |
Reference cited in the filing of the patent
______________________________________U.S. Pat. Nos.______________________________________1,443,306 Blumenthal Aug. 5, 19191,794,892 Goldsborough Mar. 3, 19311,951,643 Bald Dec. 12, 19311,900,622 Tada Mar. 7, 19331,951,645 Boosey Mar. 20, 19342,184,514 Cleesattel Sep. 27, 19372,277,758 Hawkins Mar. 31, 19422,326,872 Marsden Aug. 17, 19432,631,435 Emshwiller Mar. 17, 19532,791,900 Ruben May. 14, 19574,058,175 Holland Jul. 6, 1976______________________________________
FIELD OF THE INVENTION
The invention relates to a method of providing a deep pile foundation that can support more load weight in various soil types, and is faster to construct. The invention consists of a pre-manufactured expanding foot which is attached to a pipe shaft and extended into a prepared hole. The hole is drilled and belled at the bottom using existing methods. The expanding foot is mounted on the pipe shaft and lowered into the hole. At the bottom of the hole the foot is expanded by hammering the pipe shaft. The hammering of the pipe expands the foot and compacts the loose soil at the bottom of the hole. Concrete is pumped onto the pipe shaft from the open top and out the bottom of the pipe shaft at the foot which has been expanded by the hammering. The concrete is forced up the outside of the pipe filling the space between the pipe and the excavation. The amount of concrete needed to accomplish this is determined by substracting the known volume of the pipe shaft from the known volume of the excavated hole. When this has been accomplished the results is an expanded foot and pipe shaft incased in concrete leaving the pipe shaft hollow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a bell bottom hole;
FIG. 2 shows a plastic baggie secured at the top of the hole of FIG. 1;
FIG. 3 shows the expanding foot system located in the bell bottom hole of FIG. 1;
FIG. 4 shows additional sections of pipe secured to the expanding foot system;
FIG. 5 shows the foot system in an expanded condition;
FIG. 6 shows the expanding foot system hammered in place;
FIGS. 7 and 8 show various stages of the pumping action of the system;
FIG. 9 shows two main sections of the expanding foot system;
FIG. 10 shows the stop of the expanding foot system contacting cams which expand the foot into a bell shape;
FIG. 11 shows the expanding footing and the lower end of the section of pipe; and
FIG. 12 shows the completed base system.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a typical bell bottom hole labeled (H) which has been prepared using the standard industrial techniques. At the top of the hole a slightly larger diameter hole is excavated. An outer casing of steel or other suitable material (2) is then lowered into position in the hole. This outer casing provides protection to the top of the excavated hole, and a working surface for men and equipment. The hole is then filled with a solution of water-bentonite (1) which is common practice within the industry.
FIG. 2 shows a plastic baggie (3) which is sealed at one end and is the length of the hole's depth. The baggie is fashioned so that it may extend down the length of the hole with the sealed end at the bottom of the hole. The open end of the baggie is placed in such a fashion so that when the inner casing is fitted over the outer casing, the top of the baggie is wedged between the inner and outer casings. The purpose of the baggie is to prevent the loose soil and water-bentonite mixture from contaminating the concrete. In addition, the baggie helps to reduce the shear loading on the pile caused by the friction of the downward force of the soil around the pile as the soil settles. A water pump means (5) is then fitted into position through the inner casing and baggie such that the water pick-up means is exposed to the water-bentonite solution in the hole.
FIG. 3 shows the expanding foot system (w) is fitted to section (G) and the system is lowered through the access hole at the top of the inner casing. As the system is lowered into the hole, the baggie is drawn down into the hole. The water which is displaced by the system as the system is lowered into the hole is drawn off by the water pump means. This water may be stored in a storage tank for later use.
FIG. 4 shows additional sections of pipe (6) are added to the system as required until the system is fully lowered into the hole and the expanding foot is at the bottom of the hole. During the lowering of the system, the amount of concrete (7) which is necessary to fill the belled area and form a layer between the outside of the pipe shaft and the wall of the excavated hole is poured into the pipe shaft. On each section of pipe (6) which is added, a slip ring seal (P) made of rubber is placed such that the pipe joint (R) acts as a stop at the base of the slip ring seal preventing the seal from moving down the pipe. This seal is designed so it will allow the movement of material up the side of the pipe between the pipe and excavation, but resists movement down the outside of the pipe.
FIG. 5--Once the system is at the bottom of the hole and the necessary amount of concrete has been poured into the pipe shaft, the pipe is hammered which forces the pipe shaft into the expanding foot, expanding the foot at the bottom of the hole. Concrete (7) is pumped down the pipe and out the bottom of the expanding foot system by means of a flapper valve (Y) located in section (G), and a plug (Q) which is forced down the pipe when the necessary amount of concrete has been poured into the pipe. The pumping action is accomplished by raising and lowering the pipe. This action is illustrated in FIG. 7 and FIG. 8. As the system is raised (FIG. 8) the concrete in the pipe, being aided by pressure from the plug, travels down the pipe. The plug can be forced down the pipe be means of water or air pressure or any other such means. At the bottom of section (G) a typical flapper valve is located in such a way that when the pipe is raised, the concrete tries to flow down the center of the pipe. The flapper valve gives in this direction and allows the concrete to flow down and out the bottom of the pipe. Additionally while the pipe is being raised, the slip ring seals located on the outside of the pipe, which are designed to expand and resist movement in a relative down direction expand and assist in pushing the concrete up along the outside of the pipe. When the pipe is lowered as in FIG. 7, the flapper valve located in section (G) reacts to the back pressure of the concrete and it closes. This forces the concrete located below the flapper valve out of the expanding foot system, and up along the outside of the pipe. The slip ring seals respond to the relative up movement of the concrete and collapse allowing the concrete movement in this direction.
FIG. 6 shows what the system looks like once this pumping action is complete and the system has again been hammered until it is fully expanded and the expanded foot is driven into the bottom of the hole. This reduces the chance of later settling of the pile.
FIG. 9 show the expanding foot system is comprised of two main sections. Section (G) which is a pipe whose size is determined by the depth and support load requirements, and the expanding foot (W). Section (G) is fitted with a flapper valve near the bottom of the pipe and the flapper valve is installed such that is will allow the movement of material in the direction of the expanding foot (down) but not allow movement in the other direction (up). The top end of section (G) is fitted with a joint which will allow an additional section of pipe to be added. A slip ring (12) made of a section of steel is cut so that the section (G) can be passed through the center of the ring, and the out side diameter of the ring is the same as the outside diameter of the expanding foot. Section (G) is passed through the center of the slip ring, and a stop (11) is welded to the bottom of section (G). The stop (11) is designed so that once welded to the bottom of section (G) it will prevent the slip ring (12) from coming off of section (G) while allowing the stop to pass through the center of the expanding foot (W).
The slip ring is welded to the top of the expanding foot (W) which will allow section (G) to pass down through the expanding foot, but it will not come out when pulled.
FIG. 10 shows when section (G) is hammered down through the expanding foot (W) the stop (11) contacts the cams (8), (9), and (10) which expand the foot into the bell shape.
FIG. 11; The expanding foot (W) is a pipe which is larger in diameter than section (G) and has cuts (X) running along the length of the pipe. The amount of cuts and their distance apart may very depending on the diameter of the pipe, and the specific need of the expanding foot. The cuts usually start a short distance from the top of the foot. The cuts must be of a uniform distance apart, and for each two cuts in the foot, one bending section is created. The amount of bending sections needed for each application may very depending on the diameter of the foot. On the inside of each bending section three cams (8), (9), and (10) are welded to the section of the expanding foot between the cuts. These cams may be made as depicted or in any other fashion so that when section (G) is passed down through the expanding foot the action of the cams forces the bending section to bend as illustrated in FIG. 10. The bottom of section (W) is then sealed with a metal plate which is cut to dimension and welded into place.
FIG. 12 shows the completed process illustrated. The inner and outer casings have been removed so the top of the pile may be prepared for the required attachment as specified by the building requirements. The system is at the bottom of the hole with the expanding foot fully expanded. The concrete has been pumped down the pipe and out the expanding foot to encase the system and pipe all the way to the top of the hole. | An expanding deep base foundation system including a pre-manufactured base foot attached to the lower end of a metal shaft. The base being a length of pipe having cuts made along the length thereof. Cams are mounted on the inside of the pipe that expand the wall of the pipe foot outwardly as the metal shaft is forced through the expanding base thereby creating an enlarged base or foot. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a 35 USC 371 application of PCT/EP 2006/070201 filed on Dec. 22, 2006.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a selective freewheeling mechanism. The selective freewheeling mechanism is intended in particular for an electromechanical vehicle brake, in order to expand it into a parking brake. The invention also relates to an electromechanical vehicle brake having the selective freewheeling mechanism.
2. Description of the Prior Art
Freewheeling mechanisms are known per se and are also known as directionally-shifted clutches. A freewheeling mechanism has a shaft and an outer ring, and the shaft can also be embodied as a hollow shaft or inner ring. Between the shaft and the outer ring, there are locking elements, which allow a rotation of the shaft relative to the outer ring in one direction, the so-called freewheeling direction, and lock against a rotation of the shaft relative to the outer ring in the opposite direction, the so-called locking direction.
In a selective freewheeling mechanism, the locking elements can be put in a disengagement position, in which they are out of action, or in other words do not lock against a rotation of the shaft relative to the outer ring in any direction. In the disengagement position, the shaft is rotatable in both directions relative to the outer ring. In an engagement position, a selective freewheeling mechanism has the usual function of a freewheeling mechanism; that is, the shaft is rotatable relative to the outer ring in the freewheeling direction and is locked against rotation in the opposite locking direction.
Electromechanical vehicle brakes as wheel brakes for motor vehicles are also known. An electromechanical vehicle brake has an electromechanical actuation device, with which a fiction brake lining can be pressed for braking against a brake body that is fixed against relative rotation to a vehicle wheel. The brake body is typically a brake disk or a brake drum. The actuation device typically has an electric motor and a rotation-to-translation conversion gear that converts a rotary driving motion of the electric motor into a translational motion for pressing the friction brake lining against the brake body. Worm gears, such as spindle gears or roller worm drives, are often used as rotation-to-translation conversion gears. It is also possible to convert the rotary motion into a translational motion by means of a pivotable cam, for instance. A step-down gear, for instance in the form of a planetary gear, is often placed between the electric motor and the rotation-to-translation conversion gear. Self-boosting electromechanical vehicle brakes are also known, which have a self booster that converts a frictional force, exerted by the rotating brake body against the friction brake lining that is pressed for braking against the brake body, into a contact pressure, which presses the friction brake lining against the brake body in addition to a contact pressure that is exerted by the actuation device. Wedge, ramp, and lever mechanisms are known for the self boosting.
SUMMARY AND ADVANTAGES OF THE INVENTION
The selective freewheeling mechanism of the invention has a locking element cage, which by pivoting relative to the outer ring into an engagement position puts the locking elements in the engagement position and by pivoting relative to the outer ring into a disengagement position puts the locking elements in the disengagement position. The locking element cage, which may be embodied in a manner comparable to a roller cage of a roller bearing, puts the locking elements of the freewheeling mechanism of the invention collectively into the engagement position or the disengagement position. It is defined by this function, not by its embodiment as a “cage”. According to the invention, the locking element cage and the outer ring are embodied on the order of an electric motor, as a rotor and a stator, and have at least one coil. The locking element cage may also form the stator, and the outer ring may form the rotor. By provision of current to the at least one coil, the locking element cage can be pivoted relative to the outer ring into the engagement position and/or into the disengagement position, and as a result the locking elements can be put in the engagement position and/or the disengagement position; that is, by the provision of current to the at least one coil, the freewheeling mechanism of the invention is engaged or disengaged. Pivoting means a rotation of the locking element cage relative to the outer ring about a limited angle. In addition to a monostable embodiment, in which the freewheeling mechanism remains disengaged or engaged when without current, a bistable embodiment is also conceivable, in which when without current the freewheeling mechanism remains both in the engaged and in the disengaged position and for shifting from the engagement position to the disengagement position and vice versa, the at least one coil merely has to be supplied with current. Moreover, it is preferably provided that the at least one coil generates an axially symmetrical magnetic field.
The freewheeling mechanism of the invention has the advantage that it can be embodied rotationally symmetrically. Hence, forces acting on the freewheeling mechanism do not exert any torque on parts of the freewheeling mechanism that could cause shifting of the freewheeling mechanism. Such forces may be due to acceleration acting on the freewheeling mechanism that acts on a freewheeling mechanism of an electromechanical wheel brake of a motor vehicle while the vehicle is in motion, for instance. The invention avoids unintended shifting of the freewheeling mechanism, even at high accelerations acting on the freewheeling mechanism. Moreover, given a rotationally symmetrical magnetic field, a shifting torque for engaging and/or disengaging the freewheeling mechanism acts rotationally symmetrically on the locking element cage or the outer ring in every case. As a result, a uniform action on all the locking elements is possible; all the locking elements contribute approximately equally to locking the freewheeling mechanism in the locking direction. An additional advantage of the invention is that a separate actuator is not needed for pivoting the locking element cage for engaging or disengaging the freewheeling mechanism; the function of the actuation device is integrated with the locking element cage and the outer ring as a result of the embodiment of these parts on the order of an electric motor. This economizes in terms of installation space and makes a compact embodiment of the freewheeling mechanism of the invention possible.
Advantageously, an electromechanical vehicle brake has a selective freewheeling mechanism of the type described above. As a result, the vehicle brake is expanded to a parking brake. The freewheeling mechanism acts for instance on a motor shaft of an electric motor of an actuation device of the vehicle brake. When the freewheeling mechanism is disengaged, the motor shaft of the electric motor is freely rotatable in both rotary directions; the vehicle brake can be used as a service brake, in the same way as without a freewheeling mechanism. For locking the vehicle brake, the brake is actuated and the freewheeling mechanism is engaged; the freewheeling mechanism locks against a reverse rotation of the actuation device and thus against a release of the vehicle brake. An actuating and braking force exerted by the vehicle brake is maintained unchanged even if the vehicle brake is without current. Since the engaged freewheeling mechanism is rotatable in the freewheeling direction, an actuation or in other words tightening of the vehicle brake is possible even when the freewheeling mechanism is engaged. Because of mechanical tensing of the actuated vehicle brake, the engaged freewheeling mechanism is kept in the engagement position, in which it locks against a release of the vehicle brake. As a result of the mechanical tensing of the actuated vehicle brake, the freewheeling mechanism does not release on its own, even if it is embodied in monostable form. Not until the mechanical tensing of the vehicle brake is released by the provision of current in the actuation direction does the freewheeling mechanism release, so that the vehicle brake can then be released. It is furthermore possible for an air clearance of the vehicle brake to be adjusted, and thus to make a readjustment for wear by engaging the freewheeling mechanism upon release of the vehicle brake.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in further detail below in conjunction with exemplary embodiments shown in the drawings, in which:
FIG. 1 shows a freewheeling mechanism of the invention, seen in perspective;
FIG. 2 is a cross section through the freewheeling mechanism of FIG. 1 ;
FIG. 3 illustrates a detail marked III in FIG. 2 ;
FIG. 4 is an axial section through a modified embodiment of a freewheeling mechanism of the invention; and
FIG. 5 shows a schematic illustration of an electromechanical vehicle brake of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The freewheeling mechanism 1 shown in FIG. 1 has a tubular outer ring 2 and a locking element cage 3 disposed coaxially in the outer ring. For the sake of clarity in the drawing, a shaft that is disposed coaxially in the locking element cage 3 is not shown. The locking element cage 3 is tubular and has axially parallel, essentially rectangular openings, which are known as pockets 5 and in which cylindrical roller bodies are received that form locking elements 4 of the freewheeling mechanism 1 .
As can be seen in cross section in FIG. 2 , the shaft 6 , not shown in FIG. 1 , of the freewheeling mechanism 1 , the locking element cage 3 , and the outer ring 2 are disposed concentrically to one another; the locking element cage 3 and the locking elements 4 are located in an annular interstice between the outer ring 2 and the shaft 6 . On its inner circumference, the outer ring 2 has indentations, which are also known as pockets 7 . The locking elements 4 roll on bottom faces 8 of the pockets 7 . In the circumferential direction, the bottom faces 8 extend spirally at a wedge angle to the circumferential direction. A spacing of the bottom faces 8 of the pockets 7 of the outer ring 2 from the surface of the shaft 6 therefore decreases in a circumferential direction hereinafter called the locking direction.
For engaging the freewheeling mechanism 1 , the locking element cage 3 is pivoted about its axis in the locking direction, which is counterclockwise in terms of the drawing; that is, it is rotated far enough that the locking elements 4 come into contact with the shaft 6 . It moves the locking elements 4 in the circumferential direction; the locking elements 4 rolls on the bottom faces 8 of the pockets 7 of the outer ring 2 of the freewheeling mechanism 1 . Since the bottom faces 8 spirally approach the shaft 6 in the locking direction, the locking elements 4 come into contact with the shaft 6 and are pressed against it. The locking element cage 3 and the locking elements 4 are moved into an engagement position, not shown, and the freewheeling mechanism 1 is engaged. A rotation of the shaft 6 in the locking direction urges the locking elements 4 , pressed against it, in the locking direction, or in other words in the direction of the increasingly narrower wedge gap between the bottom faces 8 of the pockets 7 of the outer ring 2 and the shaft 6 . The locking elements 4 lock the shaft 6 by nonpositive engagement against rotation in the locking direction. In the opposite rotary direction of the shaft 6 , known as the freewheeling direction, the shaft 6 urges the locking elements 4 , pressed against it, in the direction of the increasingly larger wedge gap between the bottom faces 8 of the pockets 7 of the outer ring 2 and the shaft 6 . In this rotary direction, the shaft 6 is rotatable, with the freewheeling mechanism 1 engaged.
For disengaging the freewheeling mechanism 1 , the locking element cage 3 is pivoting in the freewheeling direction about its axis into the disengagement position shown in FIG. 2 . It moves the locking elements 4 in the circumferential direction, specifically in the freewheeling direction, up to the ends of the pockets 7 . Here, the spacing of the bottom faces 8 of the pockets 7 of the outer ring 2 from the shaft 6 is greater than a diameter of the cylindrical locking elements 4 that are embodied as roller bodies; the locking elements 4 are out of action, and the shaft 6 is freely rotatable in both rotary directions.
The locking element cage 3 is supported rotatably or pivotably in the outer ring 2 . The support is a slide bearing of the tubular locking element cage 3 in the outer ring 2 . Other bearings are possible. The rotary bearing centers the locking element cage 3 in the outer ring 2 , so that over the entire circumference, a uniform gap exists between the locking element cage 3 and the shaft 6 , and the locking element cage 3 does not scrape the shaft 6 . A transfer of torque from the shaft 6 to the locking element cage 3 and unintended engagement or disengagement of the freewheeling mechanism 1 are thereby avoided.
Spring elements 9 , which are suspended from the locking element cage 3 and engage the locking elements 4 , urge the locking elements 4 in the locking direction and into contact with one edge 10 of the pockets 5 of the locking element cage 3 , this edge being located out of sight of the locking elements 4 in the locking direction. This edge 10 is oriented obliquely outward according to the invention, so that it urges the locking elements 4 outward against the bottom faces 8 of the pockets 7 of the outer ring 2 . In the disengagement position shown in FIG. 2 , the locking elements 4 have thus been lifted from the shat 6 . The edges 10 of the pockets 5 of the locking element cage 3 may also be called contact faces for the locking elements 4 . The locking elements 4 touch the shaft 6 only when the freewheeling mechanism 1 is engaged; when the freewheeling mechanism 1 is disengaged, there is a gap between the locking elements 4 and the shaft 6 .
The enlargement shown in FIG. 3 in the region of one of the pockets 7 of the outer ring 2 shows that the bottom 8 of the pockets 7 is not at a constant wedge angle to the circumferential direction; instead, the wedge angle is greater on the end of the pockets 7 in the freewheeling direction, or in other words the right-hand end in FIG. 3 , and becomes constant or gradually more-acute in the locking direction. The initially greater wedge angle of the bottom faces 8 of the pockets 7 brings about greater lifting of the locking elements 4 away from the shaft 6 upon disengagement of the freewheeling mechanism 1 , at a predetermined pivot angle of the locking element cage 3 . When the freewheeling mechanism 1 is disengaged, the gap between the locking elements 4 and the shaft 6 is greater. Moreover, the initially greater wedge angle enables engaging the freewheeling mechanism 1 with a smaller pivot angle of the locking element cage 3 and thus makes it possible to shorten the shifting time.
The acute wedge angle in an end region, in terms of the locking direction, of the bottom faces 8 of the pockets 7 of the outer ring 2 leads to a high clamping force and thus a good locking action. In the aforementioned end region of the bottom faces 8 , the wedge angle is selected to be so acute that self-locking ensues. When the locking element cage 3 is pivoted far enough in the locking direction that the locking elements 4 are located at the acute wedge angle in the end regions, located in the locking direction, of the bottom faces 8 of the pockets 7 , then they and the locking element cage 3 , because of the self-locking, remain on their own in the locking position; that is, the freewheeling mechanism 1 in this case does not release from its engaged position. For release, either the locking element cage 3 or the shaft 6 must be pivoted in the freewheeling direction. To improve the self-locking action, an outside of the outer ring 2 is provided with recesses 11 on the end regions, located in the locking direction, of the bottom faces 8 of the pockets 7 . In those regions, a wall thickness of the outer ring 2 is weakened; in those regions, the outer ring 2 is elastic and resilient in the radial direction. As a result of the elasticity of the outer ring 2 in the aforementioned end regions of the bottom faces 8 of the pockets 7 , the locking elements 4 are pressed resiliently against the shaft 6 . Unintentional release, for instance from the pivoting motion of the shaft 6 with a small pivot angle relative to the outer ring 2 , or from vibration, is counteracted; the hold of the freewheeling mechanism 1 in the self-locking, locking engagement position is improved. The desired elasticity of the outer ring 2 in the radial direction in the region of the pockets 7 can also be attained in some other way. For instance, a housing, not shown in FIGS. 1 through 3 , and to which the outer ring 2 is pressed can have recesses on the inside in the aforementioned regions. In that case, bracing of the outer ring 2 from outside in those regions is omitted, and free spaces are created into which the outer ring 2 can yield radially outward.
In a middle region between the end regions having the large wedge angle and with the acute wedge angle that brings about the self-locking of the locking elements 4 and of the freewheeling mechanism 1 , the bottom face 8 of the pockets 7 of the outer ring 2 has a wedge angle that is so acute that self-locking ensues; that is, with the freewheeling mechanism 1 engaged, reliable locking against rotation of the shaft 6 in the locking direction is ensured under all operating conditions. However, in the aforementioned middle region of the bottom face 8 of the pockets 7 , the wedge angle is larger, or in other words more-obtuse, than in the end region, so that the freewheeling mechanism 1 does not seize in the engaged position if the shaft 6 is rotated in the locking direction.
The locking element cage 3 protrudes from the outer ring 2 on one side; in this region, it is located in a stator 12 ( FIG. 1 ) that is rigidly connected to the outer ring 2 . The stator 12 has two coils 13 located diametrically opposite one another or in other words rotationally symmetrically. The locking element cage 3 forms a rotor. The outer ring 2 with its stator 12 and the locking element cage 3 are thus embodied as a rotor and a stator on the order of an electric motor. Providing current to the coils 13 generates a rotationally symmetrical magnetic field, which exerts a torque in the locking direction on the locking element cage 3 . The freewheeling mechanism 1 can thus be engaged by the provision of current to the coils 13 . The torque engaging the locking element cage 3 is rotationally symmetrical; the locking element cage 3 is not urged transversely to the shaft 6 .
For restoration, or in other words for disengaging the freewheeling mechanism 1 , two tangentially disposed spring elements 14 are provided, which engage the stator 12 and the locking element cage 3 that forms the rotor. The restoring spring elements 14 are disposed symmetrically and likewise urge the locking element cage 3 solely rotationally symmetrically, or in other words without a resultant transverse force. In the exemplary embodiment shown of the invention the restoring spring elements 14 are embodied as helical tension springs.
The freewheeling mechanism 1 has an overall rotationally symmetrical construction, without eccentricities. Transverse forces from accelerations and jarring of the freewheeling mechanism 1 therefore do not exert any torque on parts of the freewheeling mechanism 1 that urge it in the engagement position or the disengagement position. Unintentional shifting of the freewheeling mechanism 1 is thus avoided.
In the exemplary embodiment shown, the locking element cage 3 is in one piece with the rotor; it itself forms the rotor. According to the invention, it is also possible to connect the rotor rigidly to the locking element cage 3 , for instance with a pin, rivet, and/or screw connection (not shown). As a result, the locking element cage 3 can be produced from a magnetically nonconductive material, to avoid magnetic effects on the locking elements 4 when current is supplied to the coils 13 .
On the side away from the stator 12 , the outer ring 2 protrudes past the locking element cage 3 . There, it has a shaft bearing 15 for the shaft 6 , not shown in FIG. 1 , of the freewheeling mechanism 1 . In the exemplary embodiment shown of the invention, a ball bearing has been selected as the shaft bearing 15 . Still other roller bearings or a slide bearing can also be used as the shaft bearing 15 (these options are not shown). As a result, the shaft 6 is rotatably supported and radially braced axially quite close to the freewheeling mechanism 1 , or in other words to the locking elements 4 . As a result, good coaxially of the shaft 6 in the outer ring 2 is attained, which is important for the function of the freewheeling mechanism 1 . Preferably, the shaft 6 not shown in FIG. 1 is rotatably supported and radially braced on both sides of the locking elements 4 and close to the locking elements 6 , to ensure good coaxially of the shaft 6 in the outer ring 2 even if a load is put on the shaft 6 . As a result, a locking action distributed uniformly over all the locking elements 4 is attained, which is important for proper function of the freewheeling mechanism 1 .
The locking element cage 3 has a pivot angle limitation. In the exemplary embodiment, this is formed by tabs 30 protruding radially outward from the locking element cage 3 , from which tabs the spring elements 14 for restoring the locking element cage 3 and for disengaging the freewheeling mechanism 1 are suspended. The tabs 30 cooperate with stops 31 on the stator 12 , which limit the pivot angle of the locking element cage 3 in both directions.
In the embodiment of the invention shown in FIG. 4 , the freewheeling mechanism 1 has a shiftable friction clutch 16 . The friction clutch 16 is formed by the locking element cage 3 and an annular shoulder 17 on a diameter graduation of the shaft 6 , against which the locking element cage 3 is pressed in the axial direction and by its face end upon engagement of the friction clutch 16 . When the friction clutch 16 is engaged, the shaft 6 , when it rotates, subjects the locking element cage 3 to a torque. Depending on the rotary direction of the shaft 6 , the freewheeling mechanism 1 can be engaged and disengaged as a result.
Engaging of the shiftable friction clutch 16 is done magnetically by the provision of current to a coil 18 , which is inserted into a housing 19 into which the outer ring 2 of the freewheeling mechanism 1 is pressed. The housing 19 may be a component of a housing of an electromechanical friction brake, not shown in FIG. 4 . Providing current to the coil 18 creates a magnetic field, which pulls the locking element cage 3 axially against the annular shoulder 17 of the shaft 6 and thus engages the friction clutch 16 . A magnetic circuit is closed by the housing 19 , the outer ring 2 , the locking element cage 3 , and the shaft 6 . The locking element cage 3 may also be conceived of as an armature, and the annular shoulder 17 of the shaft 6 as a pole piece, of an electromagnet that also includes the coil 18 , for engaging and shifting the friction clutch 16 . The shiftable friction clutch 16 has the advantage that the freewheeling mechanism 1 can be shifted continuously variably into any angular position.
For disengagement, the friction clutch 16 has a spring element 20 , which in the exemplary embodiment shown of the invention is embodied as a helical tension spring. The spring element 20 is screwed by one end onto a helical groove 21 of the locking element cage 3 and by the other end onto a helical groove 22 of a restoring element 23 . The restoring element 23 is tubular and is disposed coaxially to the outer ring 2 and to the shaft 6 . The restoring element 23 is pressed into the outer ring 2 and thus held axially and in a manner fixed against relative rotation. After the supply of current to the coil 18 is switched off the spring element 20 , by its spring force, pulls the locking element cage 3 axially away from the annular shoulder 17 of the shaft 6 and disengages the friction clutch 16 . Since upon engagement of the friction clutch 16 and engagement of the freewheeling mechanism 1 , the locking element cage 3 is pivoted by rotation of the shaft 6 in the rotary direction of the shaft 6 , the spring element 20 is rotated elastically. When the coil 18 is switched off, the previously elastically rotated spring element 20 exerts a restoring torque on the locking element cage 3 in the freewheeling direction, which reinforces the disengagement of the freewheeling mechanism 1 . Moreover, face ends, facing one another, of the locking element cage 3 and of the restoring element 23 have complementary sawtooth-like teeth 24 , whose direction is selected such that they likewise exert a restoring torque in the freewheeling direction and thus in the disengagement direction of the freewheeling mechanism 1 , when the locking element cage 3 is pulled by the spring element 20 against the restoring element 23 .
Otherwise, the freewheeling mechanism 1 shown in FIG. 4 is embodied identically to the freewheeling mechanism 1 shown in FIGS. 1 through 3 and described above, and functions in the same way. To avoid repetition, reference is therefore made to the aforementioned explanations of FIGS. 1 through 3 . For the same components, the same reference numerals are used.
The electromechanical vehicle brake 25 according to the invention, shown in FIG. 5 in the form of a mechanical circuit diagram, is intended as a wheel brake for a motor vehicle. It has an electromechanical actuation device 26 , with which a friction brake lining, not shown individually, can be pressed for braking against a friction clutch, such as a brake disk 27 . Such vehicle brakes are known per se in various constructions and will therefore not be described in further detail here. The actuation device 26 has an electric motor 28 , with which a rotation-to-translation conversion gear 32 , for instance in the form of a worm drive, can be driven via a step-down gear 29 . The rotation-to-translation conversion gear 32 converts a rotary driving motion of the electric motor 28 into a translational motion for pressing the friction brake lining against the brake disk 27 . To the extent described thus far, the electromechanical vehicle brake 25 is a service brake.
The selective freewheeling mechanism 1 described above is disposed on a motor shaft of the electric motor 2 . In other words, the motor shaft is the freewheeling mechanism's shaft 6 , or the two shafts are joined together in a manner fixed against relative rotation. The freewheeling mechanism 1 may also act at some other point on the actuation device 26 of the vehicle brake 25 ; for instance, it may (not shown) be disposed on a gear shaft of the step-down gear 29 . The freewheeling direction of the freewheeling mechanism 1 is selected to be in the actuation direction of the vehicle brake 25 , and the locking direction of the freewheeling mechanism 1 is selected to be in the release direction of the vehicle brake 25 . In the disengagement position of the freewheeling mechanism 1 , the vehicle brake 25 forms an actuatable and releasable service brake. Once the freewheeling mechanism 1 is engaged, the vehicle brake 25 can only be actuated, or in other words tightened, but cannot be released. A braking force once exerted is preserved. In that case, the vehicle brake 25 forms a parking brake. Since the actuated vehicle brake 25 , by mechanical tension, urges the motor shaft of the electric motor 28 in the release direction of the vehicle brake 25 and thus in the locking direction of the freewheeling mechanism 1 , the freewheeling mechanism 1 remains engaged and locked, as described further above, even when it is not supplied with current. The parking brake force, once built up, is thus maintained even when the vehicle brake 25 is without energy. Furthermore, for locking the actuated vehicle brake 25 , the locking element cage 3 can be pivoted so markedly in the locking direction that the aforementioned self-locking ensues, which keeps the freewheeling mechanism 1 in the engaged locking position. For release, the mechanical tension of the motor shaft must be reversed by supplying current to the electric motor 28 in the actuation direction, thereby disengaging the freewheeling mechanism 1 .
The foregoing relates to the preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | The invention relates to a selective freewheeling mechanism for developing an electromechanical vehicle brake (service brake) into a parking brake. The freewheeling mechanism according to the invention has an outer ring and a locking element cage which are configured as an electric motor with a rotor and a stator. The rotor and stator can be swiveled in relation to each other when a coil is supplied with current. Due to a symmetric design, the freewheeling mechanism is advantageously insensitive to acceleration forces. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a propellant augmented gas dispensing device, and more particularly to an improved pressure relief assembly for such a device.
Propellant augmented, gas dispensing devices are utilized for a variety of purposes, including the pressurization of inflatable devices, such as escape slides, life rafts, and air bag safety cushions in automobiles. Typical gas dispensing devices of this type have first and second chambers. The first chamber carries a relatively inert gas under pressure, for example carbon dioxide, while the second chamber carries a solid propellant, for example ammonium nitrate. The solid propellant is utilized as an energy source to heat and pressurize the carbon dioxide gas stored in the first chamber to temperatures on the order of 180° F. and pressures on the order of 5000 psi. Normally, the propellant will pressurize the gas in less than one second, at which time an outlet burst disc in the exhaust passage from the propellant chamber will rupture, allowing the pressurized gas to pass through the propellant chamber and out the exhaust passage. The highly pressurized gas is thus available to do useful work, for example inflate a life raft or other suitable device.
These propellant augmented, dispensing devices are designed for operation over ambient temperatures from, for example, -65° to 160° F. If a device is inadvertently exposed to temperatures in excess of the design temperatures, it is possible for the gas pressures within the device to approach the upper limit of the design pressures of the device. It is desirable for the device to have a safety mechanism that relieves the pressure within the device should it exceed a predetermined maximum. It is, however, necessary for such devices to have a burst disc or similar assembly situated between the propellant and the pressurized gas chamber. The rupture disc prevents the pressurized gas from contacting the propellant prior to ignition so that it can be properly ignited. Once the propellant is ignited, the burst disc will release propellant gases into the gas chamber after the pressure in the propellant chamber has reached a predetermined pressure, normally on the order of 500 psi higher than the stored gas pressure. On the other hand, it is desirable to relieve pressure in the gas chamber once it has reached the desired design maximum, for example on the order of 5000 psi. It is furthermore desirable to simplify the pressure relief assembly to reduce overall weight and cost. If possible, it is also desirable to combine the pressure relief assemblies into a single throw-away mechanism. Previous attempts at solving this problem have met with limited success.
SUMMARY OF THE INVENTION
In its first aspect, the present invention provides an improved pressure relief assembly for a propellant augmented, gas dispensing device. The device includes means defining a pressurized gas chamber, means defining a propellant chamber, means defining a flow passage between the gas and propellant chambers, and means defining an exhaust passage. The improved pressure relief assembly comprises a burst disc affixed in the flow passage for normally preventing flow through the flow passage. The burst disc has a propellant side and a gas side. The improved assembly also includes a support member affixed to the device and located on the propellant side of and in supporting contact with the burst disc. The support member has a central opening communicating with the flow passage. The burst disc is provided with a zone of weakness by a score line for reducing the thickness of the disc. The score line is located outwardly from the central opening. The support member supports the burst disc in the region adjacent the score line. The disc is thus capable of rupturing in the region positioned adjacent the central opening upon occurrence of a first predetermined high pressure in the gas chamber while being capable of rupturing in the opposite direction along the score line when the pressure difference between the propellant chamber and the gas chamber exceeds a predetermined low pressure on the propellant side of the disc. In this manner, a single burst disc can be employed for admitting propellant gas to the gas chamber when the propellant gas reaches a predetermined low pressure. At the same time, the same burst disc is employed for allowing pressure relief in the gas chamber should the device be exposed to temperatures exceeding design temperatures and thus causing the pressure in the gas chamber to prematurely rise beyond a predetermined maximum.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be derived by reading the ensuing specification in conjunction with the accompanying drawings wherein:
FIG. 1 is an elevation view in partial cross section of a propellant augmented, pressurized gas dispensing device illustrated prior to the insertion of the breech assembly into the pressure vessel;
FIG. 2 is a view after the breech assembly and pressure vessel have been assembled and the pressurized gas charged;
FIG. 3 is an enlarged cross-sectional view of the breech assembly and upper portion of the pressure vessel;
FIG. 4 is a view taken along view line 4--4 of FIG. 3 of the two-way burst disc constructed in accordance with the present invention;
FIG. 5 is a still further enlarged view in partial cross section of a portion of the breech assembly and the two-way burst disc;
FIG. 6 is an exploded isometric view of the two-way burst disc and the support member therefor; and
FIGS. 7 and 8 are views similar to that of FIG. 5 showing the two-way burst disc in operation.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, a propellant augmented pressurized gas dispensing device includes a pressure vessel 12 and a breech assembly 14. The pressure vessel 12 has relatively thick walls and is designed to safely store pressurized gas under pressures up to and exceeding 8000 psi. As shown in FIG. 1, the pressure vessel 12 and breech assembly 14 are illustrated prior to assembly. The sidewalls of the pressure vessel 12 are cylindrical in shape and its bottom wall is convexly shaped when viewed from the outside of the container. The vessel 12 has a top opening 18 sized to receive the breech assembly 14. The breech assembly is also cylindrical and is sized to be slidably inserted through the top opening 18 in the pressure vessel 12. The outer surface of the breech assembly 14 carries a plurality of O-rings 16 to provide seal between the assembly and the inner surface of the pressure vessel walls. During assembly, the breech assembly 14 is inserted into the opening 18 so that the upper surface 20 of the breech assembly resides below the upper lip 22 of the pressure vessel. The upper lip 22 is then swaged over the peripheral portion of the upper surface 20 of the breech assembly 14 to permanently affix the breech assembly 14 to the pressure vessel 12.
The gas dispensing device, constructed in accordance with the present invention, has no apparatus for charging the pressure vessel 12 with a pressurized gas after assembly. Instead, the gas is placed in the pressure vessel 12 during assembly of the vessel 12 and the breech assembly 14. The gas is placed in the pressure vessel 12 in a solid form, for example as block 20. The breech assembly 14 is thereafter quickly inserted through the opening 18 and the upper lip 22 of the vessel swaged to fasten the assembly 14 to the vessel 12. In a preferred form of the invention, carbon dioxide is employed as the gas. Carbon dioxide in its solid form, commonly referred to as dry ice, can be inserted in the pressure vessel and the breech assembly affixed without substantial loss of carbon dioxide gas. Moreover, the exact amount of carbon dioxide gas with which the pressure vessel 12 is charged can be precisely measured by weighing the exact amount of dry ice to be placed in the pressure vessel. In fact, the rate of sublimation of the dry ice to carbon dioxide vapor at the temperature of assembly can be calculated since the time between the placement of the dry ice in the pressure vessel 12 and the completion of assembly of the gas dispensing device can be measured and controlled. Thus, the amount of carbon dioxide vapor lost during assembly can be calculated and accounted for in the amount of dry ice initially placed in the pressure vessel. Under normal conditions, the dry ice will sublime to its vapor form at normal atmospheric temperatures. Carbon dioxide will always be available as a gas once the propellant charge in the breech assembly 14 is fired to heat and pressurize the gas in the pressure vessel 12. Charging the pressure vessel 12 with the solid form of a gas in accordance with the present invention eliminates the need for an external valve and the necessity for charging the vessel after assembly, while at the same time providing very precise control over the amount of material with which the pressure vessel is charged.
Referring now to FIG. 3, the breech assembly 14 and upper portion of the pressure vessel 12 are shown greatly enlarged. The breech assembly 14 is constructed in two major portions, a lower cup (or bulkhead) 28 and an upper lid (or closure) 30. The cup 28 and lid 30 have similar outside diameters. One of the O-rings 16 is carried by the lid while the others are carried by the cup. The upper lip 32 of the cup 28 fits into an annular groove situated on the bottom peripheral portion of the lid 30. An annular ridge 34 extends upwardly from the peripheral portion of the upper surface 20 of the lid 30. The upper lip 22 of the pressure vessel 12 is swaged over this annular ridge 34. The space between the lower surface 36 of the lid and the bottom surface 38 of the cup-shaped opening in the cup 28 defines a cylindrically shaped propellant chamber 40. An annularly shaped propellant charge 42 is sandwiched between a pair of metal screens 44 and 46 in the propellant chamber 40. U-shaped spacers 48 fit over the outer periphery of the propellant charge 42 and maintain the propellant charge 42 in spaced relationship from the sidewalls of the cup 28 and from the upper and lower surfaces, respectively, of screens 44 and 46.
The propellant chamber 40 communicates with the exterior of the gas dispensing device through an exhaust passage 50 that extends upwardly through the lid 30 at a location radially offset from the center of the chamber 40. A central, cylindrical boss 52 extends upwardly from the upper surface 20 of the lid 30. A reduced diameter threaded member 53 is formed integrally with and extends upwardly from the central portion of the boss 52. An annularly shaped exhaust filter 54 is positioned radially outwardly from the boss 52. A cap 56 has a central opening through which the threaded member 53 extends. The bottom surface of the cap 56 abuts the upper surface 58 of the boss 52 and extends radially outwardly over the exhaust filter 54 contacting the upper edge of the filter 54. The cap 56 is affixed to the boss 52 by nut 55 that is threaded onto the threaded member in abutment with the upper portion of the cap 56. The annular filter 54 thus is retained between the cap 56 and the upper surface 20 of the lid 30. The boss 52, exhaust filter 54 and cap 56 define an annular exhaust chamber 60. The exhaust passage 50 communicates with exhaust chamber 60. Thus, gas departing from the propellant chamber 40 passes through the exhaust passage 50, through the exhaust filter 54, and radially outwardly in all directions between the upper lip 22 of the pressure vessel 12 and bottom surface of the cap 56.
A high pressure burst disc 64 is mounted in a larger diameter portion 66 of the exhaust passage 50 situated adjacent the propellant chamber 40. The high pressure burst disc 64 is designed to rupture outwardly when the propellant has heated the gas to a desired level, for example, on the order of 5000 psi. A small foam disc 68 is positioned in the larger diameter portion 66 of the exhaust passage to insulate the burst disc 64.
A squib or other suitable propellant igniter 70 is mounted in a cavity provided in the central portion of the lid 30. The bottom portion of the squib communicates with the propellant chamber 40. A pair of leads 72 extend upwardly through the boss 52 and through a reduced diameter portion 53 of the boss to a location external of the gas dispensing device. These leads are the ignition leads for the squib 70 which initiates the propellant burn to pressurize the gas in the device.
Referring additionally to FIG. 5, the propellant chamber 40 communicates with the pressurized gas chamber 80 defined by the pressure vessel 12 via a flow passage 82 axially located in the cup 28 of breech assembly 14. The flow passage 82 comprises a small diameter portion 84, the upper end of which flares outwardly into a fluid communication with the propellant chamber 40. A large diameter portion 86 communicates with the gas chamber 80 while an intermediate diameter portion 88 interconnects the small diameter portion 84 and the large diameter portion. All portions of the flow passage 82 are axially aligned so that a first annular shoulder 90 is formed between the small diameter portion 84 and the intermediate diameter portion 88 and a second annular shoulder 92 is formed between the large diameter portion 86 and the intermediate diameter portion 88. Both of these shoulders face downwardly toward the gas chamber 80.
The two-way burst disc assembly 94, constructed in accordance with the present invention, is positioned in the flow passage 82. Referring now to FIGS. 4, 5 and 6, the two-way burst disc assembly 94 includes a support member 96, a burst disc 98 and a retainer ring 100. The support member 96 comprises a ring 102 having a central aperture 104. The central aperture 104 has a diameter substantially equal to that of the small diameter portion 84 of the flow passage 82. The outside diameter of the ring 102 is less than the diameter of the intermediate diameter portion 88 of the flow passage 82. Four feet 106 are affixed to portions of the upper surface of the ring 102 at equally spaced circumferential locations. The feet extend radially outwardly from the periphery of the ring 102 and have arcuate outer surfaces. These surfaces are diametrically spaced at a distance substantially equivalent to the diameter of the intermediate diameter portion 88 of the flow passage 82. The thickness of the feet 106 and ring 102 is equivalent to the depth of the intermediate diameter portion 88, that is, substantially equal to the axial distance between the shoulder 90 and the shoulder 92. The support member 96 is inserted in the intermediate diameter portion 88. The feet 106 serve to axially align the ring 102 with the flow passage 82 and serve to space the ring 102 downwardly from the shoulder 90. The bottom surface of the ring 102 is thus positioned co-planar with shoulder 92. The burst disc 98 is positioned in the large diameter portion 86 of the flow passage 82 so that the lower surface of the ring 102 abuts the upper surface of the burst disc. The burst disc is provided with a circular score line 108 having a diameter slightly larger than the outside diameter of the ring 102 but slightly less than the diameter of the intermediate diameter portion 88 of the flow passage 82, the purpose of which will be better understood when the operation of the two-way burst disc assembly 94 is described in more detail below. The outer edges of the burst disc 98 are situated adjacent the walls of the large diameter portion 86 of the flow passage 82 and thus centering the burst disc within the flow passage 82. The retainer ring 100 has a diameter substantially equal to the large diameter portion 86 of flow passage 82 and an inside diameter greater than the diameter of the intermediate diameter portion 88. The retainer ring 100 is inserted in the large diameter portion 86 and brought into abutment with the peripheral portion of the burst disc 98. The retainer ring 100 can be affixed by conventional means to the cup 28, as, for example, by welding or brazing. The burst disc 98 is thus seated by the retainer ring against the shoulder 92 and agains the bottom surface of the support ring 102.
To understand the operation of the two-way burst disc assembly 94, a normal sequence of operation for the gas dispensing device will first be described followed by a description of how the two-way valve functions to relieve over-pressure in the gas chamber 80. Referring back to FIG. 3, in normal operation, the squib 70 is fired to ignite the propellant charge 42. With some propellants, additional ignition pellets may be necessary. As the propellant burns and produces hot reaction products, the pressure differential between the propellant chamber 40 and the gas chamber 80 reaches predetermined minimum pressure on the propellant side of the two-way burst disc assembly 94, the burst disc 98 will rupture along the score line 108, the weakest zone of the disc, as illustrated in FIG. 7. The hot gaseous reaction products produced by the burning propellant then flows through passage 82 into the gas chamber 80 to heat and compress the carbon dioxide present in that chamber. When the pressure in the gas chamber 80 and the propellant chamber 40 reach a predetermined maximum, that is, a desired inflation pressure, the burst disc 64 in the exhaust passage will rupture, opening the propellant chamber 40 to the exhaust chamber 60 and thus to the apparatus to which the gas is to be dispensed.
A second advantage of the construction of the burst disc assembly shown in FIG. 7 is the provision of the annular flow passage 110 situated between the wall of the intermediate diameter flow passage 88 and the outer periphery of the ring 102 forming part of support member 96. If no annular structure were employed, but just a center hole, the burst disc would still rupture at the score line, however, when the burst disc 98 ruptures and gas begins to flow from the gas chamber 80 through the propellant chamber 40 to the exhaust passage 50, the ruptured portion 98a of the burst disc would tend to reseat over the central aperture, thus sealing the gas chamber and preventing egress of the gas. However, when the burst disc assembly is constructed in accordance with the present invention the annular flow passage 110 permits gas flow past the periphery of the ruptured portion of the disc, even though it seats over the center of the central aperture 104. As a consequence, the gas chamber can still empty through the passage 82 into the propellant chamber and thus into the exhaust passage 50.
The two-way burst disc assembly 94 thus functions in its normal operational mode to open the gas chamber 80 to the propellant chamber 40 once the propellant has been ignited. The two-way burst disc will rupture in the direction of the gas chamber at a relatively low pressure, because the score line weakens the disc. However, should the gas dispensing device be subjected to inordinately high temperatures, for example, which would cause the pressure in the gas chamber to rise, the two-way burst disc also functions as a safety valve to relieve inordinately high pressures in the gas chamber. This pressure relief function is accomplished by constructing the center portion of the disc so that it will rupture through the aperture 104 at relatively high pressures, say for example, on the order of 4000 to 5000 psi. The burst disc 98 will not rupture along the score line in the direction of the propellant chamber because it is supported by the support member 96. However, as shown in FIG. 8, the center portion 98a will rupture and blow through the aperture 104 at relatively high pressures.
The present invention has been described in relation to preferred embodiments thereof. One of ordinary skill after reading the foregoing specification will be able to effect various changes, substitutions of equivalents and other alterations without departing from the broad concepts disclosed herein. It is therefore intended that the scope of protection by Letters Patent hereon be limited only by the definition contained in the appended claims and equivalents thereof. | A propellant augmented, gas dispensing device is charged with a pressurized gas during assembly by inserting the gas in its solid form into the pressure chamber and thereafter sealing the pressure chamber. The gas is chosen so that it is in its gaseous state at normal ambient conditions. In another aspect, an improved pressure relief assembly includes a burst disc affixed to a flow passage between the pressurized gas chamber and the propellant chamber for normally preventing flow through the passage. In its preferred form, the burst disc carries an annular score line. A support member is provided on the propellant side of the burst disc and is placed in supporting contact with the burst disc adjacent the score line. The support member has a central opening communicating with the passageway to the propellant chamber. The score line is located outwardly from the central opening. The support structure allows the disc to rupture in the region of the central opening upon the occurrence of a predetermined high pressure in the gas chamber, while permitting the disc to rupture along the score line when the pressure difference between the propellant chamber and the gas chamber exceeds a predetermined low pressure on the propellant side of the disc. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to the field of ply bonding and particularly to the field of ply bonding without the use of adhesive (glue). More particularly the present invention relates to an apparatus for bonding at least two plies of a fibrous web and a corresponding method. The invention further relates to a hygiene or wiping product comprising at least two plies and obtainable by such a method.
[0002] The fibrous web may be tissue paper or nonwoven. In the apparatus, method and product of the present invention, plies of the same or a different material may be combined.
[0003] A tissue paper is defined as a soft absorbent paper having a low basis weight. One generally selects a basis weight of 8 to 40 g/m2, especially 10 to 25 g/m2 per ply. The total basis weight of multiple-ply tissue products is preferably equal to a maximum of 120 g/m2, more preferably to a maximum of 100 g/m 2 and most preferably to a maximum of 55 g/m2. Its density is typically below 0.6 g/cm3, preferably below 0.30 g/cm3 and more preferably between 0.08 and 0.20 g/cm3.
[0004] The production of tissue is distinguished from paper production by its extremely low basis weight and its much higher tensile energy absorption index (see DIN EN 12625-4 and DIN EN 12625-5). Paper and tissue paper also differ in general with regard to the modulus of elasticity that characterizes the stress-strain properties of these products as a material parameter.
[0005] A tissue's high tensile energy absorption index results from the outer or inner creping. The former is produced by compression of the paper web adhering to a dry cylinder as a result of the action of a crepe doctor or in the latter instance as a result of a difference in speed between two wires (“fabrics”). This causes the still moist, plastically deformable paper web to be internally broken up by compression and shearing, thereby rendering it more stretchable under load than an uncreped paper.
[0006] Moist tissue paper webs are usually dried by the so-called Yankee drying, the through air drying (TAD) or the impulse drying method.
[0007] The fibers contained in the tissue paper are mainly cellulosic fibres, such as pulp fibers from chemical pulp (e.g. Kraft sulfite or sulfate pulps), mechanical pulp (e.g. ground wood), thermo mechanical pulp, chemo-mechanical pulp and/or chemo-thermo mechanical pulp (CTMP). Pulps derived from both deciduous (hardwood) and coniferous (softwood) can be used. The fibers may also be or include recycled fibers, which may contain any or all of the above categories. The fibers can be treated with additives—such as fillers, softeners, such as quaternary ammonium compounds and binders, such as conventional dry-strength agents or wet-strength agents used to facilitate the original paper making or to adjust the properties thereof. The tissue paper may also contain other types of fibers, e.g. regenerated cellulosic fibres or annual plant fibres such as sisal, hemp or bamboo fibres, or synthetic fibers enhancing, for instance, strength, absorption, smoothness or softness of the paper.
[0008] If tissue paper is to be made out of pulp, the process essentially comprises a forming that includes a box and a forming wire portion, and a drying portion (either through air drying or conventional drying on a yankee cylinder). The production process also usually includes the crepe process essential for tissues and, finally, typically a monitoring and winding area.
[0009] Paper can be formed by placing the fibers, in an oriented or random manner, on one or between two continuously revolving wires of a paper making machine while simultaneously removing the main quantity of water of dilution until dry-solids contents of usually between 12 and 35% are obtained.
[0010] Drying the formed primary fibrous web occurs in one or more steps by mechanical and thermal means until a final dry-solids content of usually about 93 to 97% has been reached. In case of tissue making, this stage is followed by the crepe process which crucially influences the properties of the finished tissue product in conventional processes. The conventional dry crepe process involves creping on a usually 4.0 to 6.5 m diameter drying cylinder, the so-called yankee cylinder, by means of a crepe doctor with the aforementioned final dry-solids content of the raw tissue paper. Wet creping can be used as well, if lower demands are made of the tissue quality. The creped, finally dry raw tissue paper, the so-called base tissue, is then available for further processing into the paper product for a tissue paper product.
[0011] Instead of the conventional tissue making process described above, the use of a modified technique is possible in which an improvement in specific volume is achieved by a special kind of drying which leads to an improvement in the bulk softness of the tissue paper. This process, which exists in a variety of subtypes, is termed the TAD (Through Air Drying) technique. It is characterized by the fact that the “primary” fibrous web that leaves the forming and sheet making stage is pre-dried to a dry-solids content of about 80% before final contact drying on the yankee cylinder by blowing hot air through the fibrous web. The fibrous web is supported by an air-permeable wire or belt or TAD-fabric and during its transport is guided over the surface of an air-permeable rotating cylinder drum, the so-called TAD-cylinder. Structuring the supporting wire or belt makes it possible to produce any pattern of compressed zones broken up by deformation in the moist state, also named moulding, resulting in increased mean specific volumes and consequently leading to an increase of bulk softness without decisively decreasing the strength of the fibrous web.
[0012] The term non-woven (ISO 9092, DIN EN 29092) is applied to a wide range of products which, in terms of their properties, are located between those of paper (cf. DIN 6730, May 1996) and cardboard (DIN 6730) on the one hand, and textiles on the other hand. As regards non-woven a large number of extremely varied production processes are used, such as the air-laid and spun-laced techniques as well as wet-laid techniques. The non-woven includes mats, non-woven fabrics and finished products made thereof. Non-wovens may also be called textile-like composite materials, which represent flexible porous fabrics that are not produced by the classic methods of weaving warp and weft or by looping. In fact, non-wovens are produced by intertwining, cohesive or adhesive bonding of fibres, or a combination thereof. The non-woven material can be formed of natural fibres, such as cellulose or cotton fibres, but can also consist of synthetic fibres, such as polyethylene (PE), polypropylene (PP), polyurethane (PU), polyester, nylon or regenerated cellulose, or a mix of different fibres. The fibres may, for example, be present in the form of endless fibres of pre-fabricated fibres of a finite length, as synthetic fibres produced in situ, or in the form of staple fibres. The nonwovens according to the invention may thus consist of mixtures of synthetic and cellulose fibrous material, e.g. natural vegetable fibres (see ISO 9092, DIN EN 29092).
[0013] The fibrous web may be converted to the final hygiene or wiping product in many ways, for example, by embossing and/or laminating it into a multi-ply product, rolled or folded.
[0014] Hygiene or wiping products primarily include all kinds of dry-creped tissue paper, wet-creped paper, TAD-paper (Through Air Drying) and cellulose or pulp-wadding or all kinds of non-wovens, or combinations, laminates or mixtures thereof. Typical properties of these hygiene and wiping products include the reliability to absorb tensile stress energy, their drapability, good textile-like flexibility, properties which are frequently referred to as bulk softness, a higher surface softness and a high specific volume with a perceptible thickness. A liquid absorbency as high as possible and, depending on the application, a suitable wet and dry strength as well as an appealable visual appearance of the outer product's surface are desired. These properties, among others, allow these hygiene and wiping products to be used, for example, as cleaning wipes such as paper or non-woven wipes, windscreen cleaning wipes, industrial wipes, kitchen paper or the like; as sanitary products such as for example bathroom tissue, tissue paper or non-woven handkerchiefs, household towels, towels and the like; as cosmetic wipes such as for example facials and as serviettes or napkins, just to mention some of the products that can be used. Furthermore, the hygiene and wiping products can be dry, moist, wet, printed or pretreated in any manner. In addition, the hygiene and wiping products may be folded, interleaved or individually placed, stacked or rolled, connected or not, in any suitable manner.
[0015] Due to the above description, the products can be used for personal and household use as well as commercial and industrial use. They are adapted to absorb fluids, remove dust, for decorative purposes, for wrapping or even just as supporting material, as is common for example in medical practices or in hospitals.
[0016] To produce multi-ply tissue paper products, such as handkerchiefs, bathroom paper, towels or household towels, an intermediate step often occurs with so-called doubling in which the base tissue in the desired number of plies of a finished product is usually gathered on a common multi-ply mother reel. It is understood that (multi-ply) tissue paper products of different (multi-ply) mother reels can be further combined in subsequent converting steps.
[0017] In the final hygiene or wiping product one or more of the fibrous webs may be combined. Thereby webs of the same material, for example tissue paper or nonwoven may be combined or webs of different materials may be combined thereby forming hybrid products. In the latter a tissue paper may be combined with a nonwoven. In addition, one ply in itself may be a hybrid in regard that different types of fibres (tissue cellulosic fibres and non-woven fibres) are used in one and the same ply. A hybrid product may also be obtained in that tissue paper plies which are manufactured by different methods (for example TAD and conventional) may be combined.
BACKGROUND ART
[0018] One of various possibilities to achieve ply bonding between at least two plies of tissue paper without the use of glue is disclosed in WO-A-99/33646. The known device comprises two rollers forming a nip through which at least two plies which are to be bonded are fed. At least the outer periphery of one of the rollers is entirely covered with abrasive material such as the material used for sandpaper so as to achieve an irregular rough surface. This abrasive material is pressed into the nipped plies, whereby ply bonding is achieved.
[0019] However, an irregular rough surface structure is imprinted into at least one of the plies over the entire surface. Therefore, the outer appearance of the combined plies is irregular or the ply bonding is (almost) not visible. In addition, it will not be possible to create volume between the plies by embossing and even pre-embossed webs with a defined thickness would be flattened by compressing of the ply.
[0020] To enhance the visual appearance of the bonded plies, WO-A-99/33646 additionally suggests a subsequent embossing step. The subsequent embossing requires additional devices with the associated additional steps. This, in turn, increases the complexity of the apparatus and, hence, the manufacturing costs of the final product.
SUMMARY OF THE INVENTION
[0021] In view of the aforesaid, it is, therefore, the object of the present invention to provide an apparatus and a method for bonding at least two plies of a fibrous web (fibrous plies) without the use of adhesive, which enable the visual appearance of the bonded plies to be enhanced and the overall costs of the final product to be reduced. A further object is to provide a product that compared to the product obtained from a prior art apparatus and method as described above is improved in regard of its visual appearance, bulk (volume) and/or softness. Compared with conventional edge (border) embossing mainly used for hankies and napkins the resulting product should have an improved ply bonding when the width of the paper roll exceeds 1 m. Compared with the knurling technique, the resulting product is characterized by an improved optical appearance especially with large motives.
[0022] According to the invention, ply bonding should be carried out without using adhesives such as glue, starch, modified starch or carboxylmethylcellulose or without using adhesives based on polymers such as polyvinylalcohols, polyvinylacetates, polyurethanes, polystyrenes or based on polymers comprising acrylic or methacrylic acid.
[0023] This object is solved by an apparatus of the present invention as defined in claim 1 , a method having the features of claim 20 and a fibrous product according to claim 22 or 24 .
[0024] The basic idea of the present invention is to improve the device and method as disclosed in the prior art in that ply bonding is achieved only at discrete locations, however, still using the irregular rough surface suggested in the prior art. Therefore, the disadvantageous irregular pattern is limited to discrete locations only thereby enhancing the overall visual appearance. In addition, the ply bonding technique of the invention may be incorporated into existing devices without the need of incorporating additional rollers or associated equipment, which also leads to the advantage that creating volume by embossing (e.g. by micro-embossing or by macro-embossing) can be achieved.
[0025] Accordingly, the apparatus of the present invention comprises a first roller having an outer periphery, a plurality of embossing protuberances being provided on the outer periphery such first roller being an embossing roller. Here, the embossing protuberances may be arranged irregularly or regularly on the outer periphery providing for a regular background embossing or a decorative embossing in which the discrete embossing protuberances compliment one another to for example form a graphic representation (i.e. a dolphin, a flower, a feather etc.). Such embossing rollers can be used for micro, macro, goffra incolla or nested embossing techniques or combinations thereof. The first roller, i.e. the embossing roller should be a metal roller, preferably a steel roller. The first roller (embossing roller) can be hardened.
[0026] In addition, the apparatus of the present invention comprises a second roller having an outer periphery and being elastic or flexible at least in a radial direction and together with the first roller forming a nip through which the at least two plies are to be fed. In this context, the second roller may be the marrying roller or the counter roller of pre-existing systems. The second roller should comprise a hard surface layer based on a flexible and elastic support layer so that the second roller is flexible and reversible regarding deformation. In addition, such a second roller should also comprise a core normally made of hard materials such as steel.
[0027] Furthermore, the present invention provides an irregularly rough surface on at least part of the outer periphery of at least one of the first and the second roller wherein the irregularly rough surface is arranged on the respective roller so that the at least two plies are bonded at discrete locations only, namely at the locations corresponding to at least some of the embossing protuberances. These features, on the one hand, enable the apparatus to achieve ply bonding between at least two plies of tissue paper which is sufficiently strong to hold the plies together and, on the other hand, enables, in only one device, to obtain an, in regard of the visual appearance, advantageous embossing pattern and achieve ply bonding by means of the irregularly rough surface. Due to the fact that the ply bonding is obtained only at discrete locations corresponding to at least some of the embossing protuberances, no irregularly background imparting over the entire surface of the plies exists so that the overall appearance of the multiply product achieved by the present invention is improved at the same time imparting an embossing to the plies to increase the bulk.
[0028] In one particular embodiment of the present invention, the embossing protuberances have a top surface opposite to (facing) the outer periphery of the second roller and the irregular rough surface is disposed on the top surfaces of at least some and possibly all embossing protuberances.
[0029] Further, it is possible to provide the first roller with at least two kinds of embossing protuberances, namely first protuberances having a first height in a radial direction of the first roller and second protuberances having at least a second height in the radial direction of the first roller, the first height being larger than the second height. In this context, the lower protuberances, i.e. second protuberances, may form a regular background pattern and the first protuberances having the larger height may form the aforesaid decorative or graphic pattern. In this particular case, it is preferred that the irregular rough surface is disposed on the top surfaces of at least some of the first protuberances only, though it is also possible to provide the irregular rough surface on all protuberances, i.e. the first and second protuberances. It is advantageous, if the ply bonding is not achieved at all, but only at some of the first protuberances, because the plies are then shiftable relative to each other in the unbonded areas. This leads to a softer feeling and an increased bulk. As far as the configuration of different kinds of protuberances on the outer periphery of an embossing roller are concerned, the skilled person is referred to for example EP-A-0 765 215.
[0030] In another particular embodiment of the present invention, it is preferred that the irregular rough surface is disposed on at least part of the outer periphery of the second roller opposite to the embossing protuberances. In this context, it is even conceivable to cover the entire outer periphery of the second roller with the irregular rough surface because only the top surfaces of the protuberances will form the nip together with the outer periphery of the second roller so that ply bonding is achieved only at the discrete locations. This particular embodiment may be alternative to the particular embodiments named above but it may even be preferred to combine these embodiments.
[0031] The irregular rough surface may be disposed onto the outer surface of either the first roller or the second roller by using ordinary techniques such as flame spraying, thermospraying processes, laser sintering or galvanic application techniques. If the irregular rough surface is to be disposed onto the surface of the second roller, it is also possible to insert hard particles onto or into the rubber material by kneading before such rubber material is being coated onto the core of the second roller. If such hard particles are being added to the rubber material by kneading the rubber at the time it is still deformable, such hard particles may be located in the surface of the rubber layer as well as beyond its surface. In case that the upper part of the surface of the rubber layer will be removed during ply bonding due to abrasive forces, the second roller still has a rough surface because the sublayer located beyond the surface of the rubber layer also comprises hard particles.
[0032] The second roller may be a rubber roller having at least one rubber layer. However, it is also preferred to use a multilayer rubber roller as described for example in DE-U-20 2007 006 100 or to use a so called paper roller, a steel roller coated with compressed paper.
[0033] Alternatively, it is also conceivable to use a metal plated rubber roller such as the marrying rollers sold by Fabio Perini (WO 2004/065113).
[0034] The rubber used in the second rubber rollers (counter rollers or marrying roller) should be an elastic material and may be selected from the group consisting of NR (natural rubber), EPDM (ethylen-propylen-dien-caoutchouc), NBR (nitrile-butadien-rubber) and PU (polyurethane). The rubber may contain fillers like suede or graphite, carbon black, silica caolin, dyes and pigments as well as aging inhibitors. Further additives are catalysts, activators, plasticizers or cross-linking agents.
[0035] If the second roller is a counter roller, such counter roller may consist either of rubber, of paper or of metal. If the counter roller consists of rubber, it is preferred that such second roller has a hardness at the outer periphery between 25 and 80, preferably between 35 and 70, most preferably of about 50 Shore A. If such roller consists of paper, it is preferred that compressed paper should be used. If such roller consists of metal, it is preferred that steel should be used. The surface of such counter roller may be either flat or structurized and should preferably comprise the negative shape of the embossing roller, so that the counter roller and the embossing roller match with each other.
[0036] In case the second roller is the marrying roller of pre-existing systems, it is preferred that the second roller has a hardness at the outer periphery between 80 Shore A and 80 Shore D, preferably between 90 Shore A and 70 Shore D, most preferably of between 95 Shore A and 60 Shore D. Preferably a marrying roller is used, whereby a core made of steel is coated with a flexible middle layer and onto said middle layer an additional layer made of metal is being coated. If such a marrying roller is characterized by a rough surface, hard particles should be added onto the metallic outer layer of the marrying roller.
[0037] The hardness of so called elastic materials is in general determined according to the method of Shore (DIN 53505). The hardness of the material in general is a measure for the resistance of this material against the penetration of a harder solid body. In the method according to Shore different devices for determining the hardness are used for softer materials (Shore A) and harder materials (Shore D). This results in two hardness scales for softer materials in the range of 10-98 Shore A and for harder materials in the range of 30-90 Shore D. Suitable devices for measuring the hardness according to Shore A and Shore D are available from Zwick GmbH & Co., Ulm. Thereby conical penetration bodies are pressed against the material to be measured by about 2.5 mm, wherein the force needed for this penetration is measured. Based on the measured force the Shore hardness is calculated.
[0038] As previously mentioned, the irregular rough surface is of that kind used for sandpaper. Accordingly, it is preferred that the outer periphery of at least one of the first and the second rollers is entirely or partly covered with hard particles similar to that used for sandpaper, i.e. hard material.
[0039] In this context, it is particularly preferred that the hard particles are selected from the group consisting of ceramics, diamonds, corundum, silicon carbide, bore nitride, tungsten carbide, metal and aluminium oxide or combinations thereof. If is further preferred that the particles have a MOHS-hardness of 4 or more according to the MOHS-hardness scale.
[0040] Further, it is preferred that the particles have a size between 40 and 1000 μm. This size is particularly preferred from the view point of achieving connections between the individual fibres of the corresponding tissue plies to obtain fibres bonding. The granulation range is between P10 to P240, particularly P60 to P150 and more particularly between P100 and P140. The most preferred granulation range is P120 (DIN ISO 6344, volume 2000-04, Part 1-3).
[0041] In this context, it is the aim to make as many “roughness edges” available as possible per unit area of the tissue papers to produce ply adhesion. In this context, particular reference is made to WO-A-99/336646.
[0042] To enhance the ply bonding between the at least two plies, it is preferred to provide at least one discharge device upstream of the first and second rollers to electrically discharge at least one, preferably all plies. In this context, a copper garland may be used which hangs over the fed web constituting the plies. Alternatively, a high voltage discharge device may be used.
[0043] In addition, it may be appropriate to enhance the moisture level of the plies to be bonded which, on the one hand, has an advantageous effect with respect to the electrostatic charge of the tissue plies and, on the other hand, also enhances the strength of the ply bonding. For this purpose, it may be preferred to add a fluid applicator for applying a fluid with polar groups on at least one of the plies upstream of the first and second rollers to increase the fluid content of the ply. This fluid applicator may be formed by nozzles, a rotating disk system or a slot nozzle system. In addition slit bars may be used, wherein the tissue plies are moved over the bar. Also steam application or fog application are conceivable. In addition, the fluid applicator may be a simple fountain system.
[0044] Suitable fluids with a polar group are e.g. aliphatic or aromatic alcohols, aliphatic or aromatic carbon acids including their ester or amide or anhydride derivatives and aliphatic or aromatic amines including mixtures of such fluids. Preferably water is used as a fluid to be applied onto the ply. It is understood that such fluids should be liquid at such temperatures ranges at which ordinary embossing stations are being operated.
[0045] It is preferred that the fluid applicator is configured to apply the fluid on the ply at a plurality of discrete locations so as to increase the fluid content of the ply locally only. In particular, the fluid is applied locally only in the areas in which the two plies are bonded to increase the fluid content, preferably the water content only in these areas and improve the bonding strength. This may be achieved by an alternative possibility, namely in that the fluid applicator is configured for applying a fluid on at least some of the embossing protuberances of the first roller upstream of the nip between the first and second rollers to increase the fluid content of the ply locally. In context of these embodiments, it is to mention that the amount of fluid on the ply should reside in a local range of 0.1 to 30 g/m 2 , preferably between 0.2 and 6 g/m 2 and more preferably between 0.5 and 3 g/m 2 . These ranges should refer to local areas e.g. to embossing protuberances or ply bonding areas.
[0046] In this context and for cost reasons, it is preferred that the fluid is water. However the fluid may also be an ink, especially a water based ink. Most of the tissue products which are hitherto produced are printed.
[0047] In addition to the inventive apparatus, the present invention also suggests a method for bonding at least two plies of tissue paper comprising the steps of: transferring at least two plies between two rollers forming a nip and imprinting an irregular rough surface of at least one of the rollers into at least one of the plies at a plurality of discrete locations of the plies, so that the two plies are bonded together at the discrete locations, whereby one roller is an embossing roller with protuberances and the other roller is a counter roller or a marrying roller.
[0048] According to a preferred method for bonding plies, hard particles disposed on at least one of the rollers are imprinted into the plies. Ply-bonding is carried out mainly by using mechanical forces.
[0049] Further, the present invention also suggests a fibrous product obtainable by a method as explained above.
[0050] The fibrous product of the invention comprises at least two plies of a fibrous web, wherein at least one of the plies has an embossed pattern of discrete embossing elements. The two plies are mechanically bonded together without the use of adhesive or glue, on at least some of the embossing elements. According to the inventive fibrous product, the area of the product in which the embossing elements at which the two plies are bonded together are located has a non-uniform transparency. In this context, it is to be mentioned that the embossing elements at which the two plies are bonded define an area of the product at which the two plies are bonded together. This area at different locations of the area has a different transparency. That is at least two different transparencies are located within that area.
[0051] Contrary to fibrous tissue products of the prior art such as hankies or facials, whereby the plies are being bonded together by mechanical means without using adhesives or contrary to tissue products whereby ply bonding is carried out by using ultra radiation, the fibrous products of the present invention are further characterized by a transparency which is different in terms of location onto the protuberances (non-uniform). In addition, the fibrous products of the present invention are characterized by an improved visual appearance.
[0052] Preferably, the two plies are bonded together only at the at least some of the embossing elements and, as previously mentioned with respect to the apparatus and method for manufacturing the product, the product is at least colored in the area in which the plies are bonded, that is in the area where the embossing elements at which the two plies are bonded together are located.
[0053] The products according to the present invention are characterized by an extraordinary high ply-bonding strength if such products contain no or just a low amount of wet strength agents.
[0054] Further features and advantages as well objects of the present invention will become apparent from the following description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] The description of the particular embodiments of the present invention makes reference to the accompanying drawings in which:
[0056] FIG. 1 a shows a schematic view of an inventive apparatus according to a first embodiment of the present invention and FIG. 1 b shows a product obtained by using the apparatus of FIG. 1 a;
[0057] FIG. 2 a shows a schematic view of an inventive apparatus according to a second embodiment of the present invention and FIG. 2 b shows a product obtained by using the apparatus of FIG. 2 a ; and
[0058] FIG. 3 a shows a schematic view of an inventive apparatus according to a third embodiment of the present invention and FIG. 3 b shows the respective product.
[0059] Throughout the figures the same or equivalent elements are referred to by the same reference numerals.
[0060] It is understood that in addition to the embossing steps described in the detailed description other converting steps such as printing, application of additives, lotions or scents, cutting, perforating or folding may be carried out.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] FIG. 1 a shows an apparatus according to a first embodiment of the present invention. Such apparatus in its structural features beside the following differences is similar to an apparatus for embossing and ply bonding in a nested configuration. In regard of these prior art apparatuses reference is made to for example WO-A-2006/136 186.
[0062] The inventive apparatus comprises a first roller 10 and a second roller 20 .
[0063] The first roller 10 is an embossing roller made of steel. The embossing roller comprises a plurality of the embossing protuberances (not shown) being provided on the outer periphery. In one preferred embodiment, the embossing protuberances have top surfaces covered with hard particles having a granulation of P120 (DIN ISO 6344, volume 2000-04 part 1-3).
[0064] The second roller 20 is a marrying roller and may be formed of rubber the outer periphery being covered by a metal layer (e.g. metal plated rubber roller of Fabio Perini (WO 2004/065113). The outer surface of the marrying roller 20 may entirely be covered with the same or another abrasive material.
[0065] Additionally, there is provided a counter roller 9 for the embossing roller 10 which is made of rubber.
[0066] The apparatus shown in FIG. 1 a further comprises a second embossing roller 11 having embossing protuberances on an outer periphery and a counter roller 12 made of rubber. The embossing roller 10 and the embossing roller 11 are associated to each other so that the corresponding embossing protuberances match. A small gap should be between the embossing rollers 10 and 11 .
[0067] An applicator for applying fluid, especially a water based fluid on the one side of one ply is provided in association with the embossing roll 10 . This applicator comprises a fluid applicator roller 8 , an anilox roller 7 and a fluid reservoir 6 (doctor chamber). Such a common fluid applicator may be used to apply fluid, wherein preferably a fluid comprising ink is used. Such application systems for fluids normally consists of an applicator roller, a transfer roller and a reservoir of fluid and can also be designed as a so-called immersion roll system in which the transfer roller is immersed into the reservoir of fluid and transports fluid by means of surface tension and adhesive forces out of the reservoir of fluid. By adjusting the gap between the transfer roller and the applicator or application roller, the amount of fluid to be applied can be adjusted. Application rollers may be structured rollers. Transfer rollers having defined pit-shaped depressions in their circumferential surface can also be used. Such transfer rollers are known as anilox-rollers. Such a roller is usually made of ceramic material or it is a roller made of steel or copper and coated with chromium. Excessive fluid is removed from the surface of the anilox-roller by means of a blade. The amount of fluid is determined by the volume, the number of depressions and the difference in speed between the anilox roller and the applicator roller. Alternative application systems are based on a spraying equipment (e.g. Weko-technique, Dynatee) or contract systems like slot dyes (Nordson).
[0068] The two plies are guided through the corresponding roller nips by means of several guide rollers 5 . Additionally web tension control systems (not shown) can be useful.
[0069] The function of the apparatus as shown in FIG. 1 a is as follows.
[0070] Two single plies are fed to the apparatus and separated at the first guide roller 5 , one of the plies 14 being guided around (this is not essential, also other guiding paths are conceivable) the rubber roller 9 and the other ply 13 being guided via other guide rollers 5 to a nip formed between the second embossing roller 11 and the second counter roller 12 . Between this nip a first embossing pattern is imparted to the ply 13 . The other ply 14 is transferred into the nip between the counter roller 9 and the first embossing roller 10 to form a second embossing pattern on the ply 14 .
[0071] Then water or a water based ink is taken from the reservoir 6 and transferred by means of the anilox roller 7 from the reservoir 6 to the applicator roller 8 . The applicator roller 8 then transfers the water based fluid (water or water based ink) on the side of the ply 14 which faces the applicator roller 8 . Preferable amounts of fluid reside within 0,1 to 30 g/m 2 , 0,2 to 6 g/m 2 and most preferably between 0,5 to 3 g/m 2 . Such fluid should preferably be applied locally and not on the entire surface of the ply. In addition, because of the transfer into the nip performed between the rubber roller 9 and the embossing roller 10 , only areas of the ply corresponding to the top surfaces of the embossing protuberances on the embossing roller 10 come in contact with the outer periphery of the applicator roller 8 so that only these parts of the ply 14 are moistened or printed by the water based ink. Then both plies 14 and 13 subsequently are bonded in the nip formed between the embossing roller 10 and the marrying roller 20 . In this nip the hard particles on the top surfaces of the embossing protuberances of the embossing rollers 10 at least partly penetrate into the fibre structure of the two plies 13 , 14 so that fibres of both webs are interconnected. As the hard particles are only provided on the top surfaces of the protuberances on the embossing roller 10 , the ply bonding is only achieved in these areas.
[0072] Afterwards, the two plies being combined leave the marrying roller 12 and are further processed and converted to a final product.
[0073] FIG. 1 b discloses the product obtained by using the apparatus of FIG. 1 a . Plies 14 and 13 are being bonded together at depressions ( 30 ) (referring to the protrusions of the embossing roller) of ply 14 . These ply bonding areas are colored because a water-based fluid comprising ink is being applied onto the embossing roller 10 .
[0074] The embodiment shown in FIG. 2 a differs from the apparatus shown in FIG. 1 a in that a so called Goffra Incolla apparatus is used as the basis. This apparatus comprises the same elements as the apparatus in FIG. 1 a but omits the second embossing roller 11 and its counter roller 12 .
[0075] In this apparatus the first ply 14 is guided into a nip between the rubber roller 9 and the embossing roller 10 , the rubber roller 9 being the counter roller. The embossing roller 10 has background embossing protuberances of height h 2 and décor embossing protuberances of height h 1 , whereby h 1 >h 2 . The heights of the background embossing protrusions are preferably between 0.2 and 0.8 mm lower than those of the décor embossing protrusions. In this nip an embossing pattern is imparted on the first ply 14 by the protuberances provided on the outer periphery of the embossing roller 10 . As in FIG. 1 a water or water based ink is applied to the ply 14 in an area corresponding to the top surfaces of the first protuberances, wherein a difference in the circumferential speed of the transfer roller and the applicator roller is adjusted. Subsequently, the first ply 14 and the second ply 13 are brought together in a nip between the embossing roller 10 and a marrying roller 20 , wherein the top surfaces of the protuberances of the embossing roller 10 and/or the outer periphery of the marrying roller 20 is provided with hard particles. In any case, because the nip between the roller 10 and the marrying roller 20 is only formed between the top surfaces of the protuberances and the outer periphery of the marrying roller 20 enough pressure for the hard particles to penetrate into at least part of both plies is only achieved at the areas of the top surfaces of the first embossing protuberances (e.g. if the marrying roller has a diameter of 260 mm and the embossing roller 10 has a diameter of 280 mm a nip of 8-10 mm is adjusted, the marrying roller having a rubber hardness of 95 Shore A and a 1,5 mm thick steel band). So the ply bonding is only achieved in these areas. Subsequently, both plies being combined are further transferred to other processing steps, if required.
[0076] FIG. 2 b discloses a two ply product obtained by using the apparatus of FIG. 2 a . Plies 14 and 13 are being bonded together at depressions 30 (referring to the first protrusions of the embossing rollers) of ply 14 . Ply 14 comprises smaller depressions 40 which do not contribute to the ply bonding because these depressions 40 have a reduced height compared to depressions 30 .
[0077] An alternative apparatus is shown in FIG. 3 . Compared to the apparatus shown in FIG. 2 the apparatus of FIG. 3 omits the rubber roller 9 .
[0078] Instead, the first ply 14 is transferred into the nip between the applicator roller 8 and the embossing roller 10 to apply the water based fluid on the side of the ply 14 in the areas corresponding to the top surface of the protuberances of the embossing roller 10 . Then, the second ply 13 together with the first ply 14 are being transferred into the nip and bonded together in the nip between the embossing roller 10 and the rubber roller 20 , ply bonding is achieved in the areas corresponding to the top surfaces of the embossing protuberances. There is no or only a slight embossing achieved. For this purpose, either the top surfaces of the embossing protuberances and/or the entire outer periphery of the marrying roller 20 are coated with hard particles.
[0079] FIG. 3 b discloses a two ply product obtained by using the apparatus of FIG. 3 a . Plies 14 and 13 are being bonded together at areas 50 which do not show the typical shape of embossing protrusions because neither ply 14 nor ply 13 is characterized by an embossing pattern. | Apparatus for bonding at least two plies of fibrous web, includes: a first roller having an outer periphery, a plurality of embossing protuberances being provided on the outer periphery, such first roller being an embossing roller; and a second roller having an outer periphery and being elastic at least in a radial direction and together with the first roller forming a nip through which the at least two plies are be fed, such second roller being a counter roller or a marrying roller, wherein at least a part of the outer periphery of at least one of the first and the second roller is irregularly rough so that the at least two plies are bonded at discrete locations corresponding to at least some of the embossing protuberances. A multi-ply product including the bonded plies and a corresponding method are also described. | 8 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/841,550, filed Sep. 1, 2006, which is incorporated herein by reference in its entirety.
STATEMENT OF FEDERAL SUPPORT
[0002] The subject matter of this application was sponsored in part by the federal government under National Science Foundation grant no. NSF CHE 0415369, and the government has certain rights in the application.
BACKGROUND
[0003] Conducting polymers, or polymers that have conjugation in their backbone, can be used in many commercial applications including for example OLEDs, PLEDs, photovoltaic cells, transistors, sensors, and the like. See, for example, The Encyclopedia of Polymer Science and Engineering , Wiley, 1990, pages 298-300, including polyacetylene, poly(p-phenylene), poly(p-phenylene sulfide), polypyrrole, and polythiophene; see also U.S. Pat. Nos. 6,602,974 to McCullough et al. and 6,166,172 to McCullough et al., as well as “The Chemistry of Conducting Polythiophenes,” by Richard D. McCullough, Adv. Mater. 1998, 10, No. 2, pages 93-116 and Handbook of Conducting Polymers, 2 nd Ed. 1998, Chapter 9, by McCullough et al., “Regioregular, Head-to-Tail Coupled Poly(3-alkylthiophene) and its Derivatives,” pages 225-258. In many cases, commercial applications compel that these polymers be free of metallic impurities. For example, nickel and magnesium impurities represent typical problems. This can be a challenge however because large amounts of metals can be used in preparing these polymers including magnesium and nickel which may stubbornly persist in the material despite careful workup. Conducting polymers can aggregate and trap impurities, and solubility can be difficult. However, extensive purification can be economically unattractive. Metallic impurities can alter and reduce properties and generally generate confusion in data interpretation. In many cases, one should note the purification methods used for preparing the polymer in reporting the properties of the polymer or devices using the polymer. See for example US Patent Publication 2004/0250849 to Chen et al.; Erwin et al, “Effects of Impurities on the Optical Properties of Poly-3-hexylthiophene Thin Films,” Thin Solid Films, 409 (2002) 198-205. Problems of metallic impurities are particularly relevant to development of polythiophenes and regioregular polythiophenes.
[0004] A general need exists to find a versatile, inexpensive, convenient, commercially attractive method to purify polymers, particularly for electronic applications and those involving electric current flow, fields, and interaction with light. The polymers should be electronics grade: high quality and high purity enabling high mobility performance. Relevant applications include organic electronic applications including RFID chips, solar cells, FETs, OLEDs, and PLEDs. Commercial scale should be possible with multi-kg batches. For example, a need exists to prepare polymers for both bench work and at commercial scale wherein the total metal content is less than 50 ppm, the contents of magnesium and nickel are each undetectable, and the amount of iron is also reduced to below 50 ppm.
[0005] U.S. Pat. No. 6,894,145 provides one approach based on extraction.
SUMMARY
[0006] Provided herein are methods of purifying polymers, methods of using purified polymers, purified polymers, and devices made from purified polymers.
[0007] One embodiment provides a method comprising: (i) providing a first solution comprising a soluble conducting polymer and first solvent system, (ii) providing a second solution comprising at least one metal complexing agent and a second solvent system which is adapted to precipitate the conducting polymer, (iii) combining the first solution with the second solution to precipitate the conducting polymer, (iv) isolating the precipitated conducting polymer.
[0008] Another embodiment is a method comprising: providing a first solution comprising a soluble polythiophene, providing a second solution comprising at least one metal complexing agent, combining the first solution with the second solution to precipitate the polythiophene, and isolating the precipitated polythiophene.
[0009] Another embodiment is a method comprising: providing a first solution comprising a soluble regioregular polythiophene, providing a second solution comprising at least one metal complexing agent, combining the first solution with the second solution to precipitate the regioregular polythiophene, isolating the precipitated regioregular polythiophene.
[0010] Another embodiment is a method comprising: providing a first solution comprising a soluble conducting polymer and first solvent system, providing a second solution comprising (i) at least one agent which can undergo ligand exchange with a nickel phosphine compound and (ii) a second solvent system which is adapted to precipitate the conducting polymer, combining the first solution with the second solution to precipitate the conducting polymer, and isolating the precipitated conducting polymer.
[0011] Advantages of one or more of the embodiments described herein include better polymer properties and better performance when used in devices, more soluble polymers, better analytical data, and higher mobilities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates nickel thiophene bond cleavage with HCl treatment for one metal containing polythiophene polymer in need of purification.
[0013] FIG. 2 illustrates ligand exchange of nickel phosphine catalyst for one metal complexing agent.
DETAILED DESCRIPTION
Introduction
[0014] All references cited herein are hereby incorporated by reference in their entirety.
[0015] A first embodiment provides a method comprising:
[0016] providing a first solution comprising a soluble conducting polymer and first solvent system,
[0017] providing a second solution comprising at least one metal complexing agent and a second solvent system which is adapted to precipitate the conducting polymer,
[0018] combining the first solution with the second solution to precipitate the conducting polymer,
[0019] isolating the precipitated conducting polymer.
[0020] Another embodiment provides the soluble conducting polymer as a heterocyclic polymer.
[0021] Yet another embodiment provides the soluble conducting polymer as a polythiophene.
[0022] Yet another embodiment provides the conducting polymer as a regioregular polythiophene or a block copolymer comprising a regioregular polythiophene.
[0023] Yet another embodiment provides the conducting polymer as a regioregular polythiophene homopolymer or copolymer.
[0024] Yet another embodiment provides the conducting polymer as a 3-substituted polythiophene.
[0025] Yet another embodiment provides the conducting polymer as a 3-alkyl or 3-alkoxy substituted polythiophene.
[0026] Another embodiment provides a further step of preparing the conducting polymer with use of nickel and magnesium compounds.
[0027] Yet another embodiment provides a further step of preparing the conducting polymer with use of Grignard metathesis polymerization.
[0028] Yet another embodiment provides a further step of preparing the conducting polymer by polymerization of a thiophene monomer.
[0029] Another embodiment provides that the first solvent system comprises at least one organic solvent.
[0030] Yet another embodiment provides that the first solvent system comprises at least one organic solvent and acid.
[0031] Yet another embodiment provides that the first solvent system comprises at least one etheric solvent.
[0032] Another embodiment provides that the first solution comprises nickel and magnesium total content before purification of at least 1,000 ppm.
[0033] Another embodiment provides that the second solution is not substantially water.
[0034] Another embodiment provides that the metal complexing agent comprises a chelating compound with at least two binding groups.
[0035] Yet another embodiment provides that the metal complexing agent comprises a chelating compound with at least two nitrogen binding groups.
[0036] Yet another embodiment provides that the metal complexing agent comprises a chelating compound comprising at least two oxime groups.
[0037] Yet another embodiment provides that the metal complexing agent comprises a glyoxime compound.
[0038] Yet another embodiment provides that the metal complexing agent comprises dimethylglyoxime.
[0039] Yet another embodiment provides that the metal complexing agent comprises a crown ether.
[0040] Yet another embodiment provides that the metal complexing agent comprises a compound comprising a plurality of oxygen atoms.
[0041] Yet another embodiment provides that the complexing agent comprises a polymer comprising a nitrogen atom.
[0042] Yet another embodiment provides that the complexing agent comprises a polymer comprising a nitrogen atom in the side group.
[0043] Yet another embodiment provides that the complexing agent comprises an acrylamide or pyridine functional group.
[0044] Another embodiment provides that the first solution comprises at least two metal complexing agents
[0045] Another embodiment provides that the amount of the metal complexing agent is at least about 0.1 g/100 mL of second solution.
[0046] Yet another embodiment provides that the amount of the metal complexing agent is at least about 0.5 g/100 mL of second solution.
[0047] Yet another embodiment provides that the amount of the metal complexing agent is at least about 1.0 g/100 mL of second solution.
[0048] Another embodiment provides that the adding step is carried out at about 15° C. to about 40° C.
[0049] Another embodiment provides that after the adding step, stirring is carried out for at least one hour.
[0050] Another embodiment provides that the isolating step comprises filtration, extraction, and drying.
[0051] Another embodiment provides that the isolated polymer comprises no residual ash in elemental analysis.
[0052] Another embodiment provides that the isolated polymer provides an ICP-MS nickel analysis of less than 1 ppm.
[0053] Yet another embodiment provides that the isolated polymer provides an ICP-MS magnesium analysis of less than 1 ppm.
[0054] Yet another embodiment provides that the isolated polymer provides an ICP-MS magnesium analysis and an ICP-MS nickel analysis both less than 1 ppm.
[0055] Yet another embodiment provides that the isolated polymer provides an ICP-MS nickel or magnesium analysis of less than 20 ppm.
[0056] Yet another embodiment provides that the isolated polymer provides a total metal content of less than 50 ppm.
[0057] Another embodiment provides that the combining step is carried out only once prior to the isolating step.
[0058] Another embodiment provides there is no two-phase separation step, liquid extraction step, or solid extraction step prior to the isolating step.
[0059] A second embodiment provides a method comprising:
[0060] providing a first solution comprising a soluble polythiophene,
[0061] providing a second solution comprising at least one metal complexing agent,
[0062] combining the first solution with the second solution to precipitate the polythiophene,
[0063] isolating the precipitated polythiophene.
[0064] A third embodiment provides a method comprising:
[0065] providing a first solution comprising a soluble regioregular polythiophene,
[0066] providing a second solution comprising at least one metal complexing agent,
[0067] combining the first solution with the second solution to precipitate the regioregular polythiophene,
[0068] isolating the precipitated regioregular polythiophene.
[0069] A fourth embodiment provides a method comprising:
[0070] providing a first solution comprising a soluble conducting polymer and first solvent system,
[0071] providing a second solution comprising (i) at least one agent which can undergo ligand exchange with a nickel phosphine compound and (ii) a second solvent system which is adapted to precipitate the conducting polymer,
[0072] combining the first solution with the second solution to precipitate the conducting polymer,
[0073] isolating the precipitated conducting polymer.
[0074] Another embodiment provides a purified polymer prepared by the method according to the first, second, third, or fourth embodiments.
[0075] Yet another embodiment provides a device comprising the purified polymer prepared by the method according to the first, second, third, or fourth embodiments.
[0076] Another embodiment provides a soluble conducting polymer, wherein the total metal content of the soluble conducting polymer is about 50 ppm or less.
[0077] Yet another embodiment provides a soluble conducting polymer, wherein the total metal content of the soluble conducting polymer is about 50 ppm or less, and wherein the polymer is a soluble polythiophene.
[0078] Yet another embodiment provides a soluble conducting polymer, wherein the total metal content of the soluble conducting polymer is about 50 ppm or less, and wherein the polymer is a soluble regioregular polythiophene.
[0079] Another embodiment provides that the polymer of the first embodiment is a block copolymer.
[0080] Yet another embodiment provides that the polymer of the first embodiment is a block copolymer comprising a polythiophene segment.
[0081] Yet another embodiment provides that the polymer of the first embodiment provides no residual ash in elemental analysis.
[0082] Yet another embodiment provides that the polymer of the first embodiment provides an ICP-MS nickel analysis of less than 1 ppm.
[0083] Yet another embodiment provides that the polymer of the first embodiment provides an ICP-MS magnesium analysis of less than 1 ppm.
[0084] Yet another embodiment provides that the polymer of the first embodiment provides an ICP-MS magnesium and an ICP-MS nickel analysis each of less than 1 ppm.
[0085] Another embodiment provides a device comprising a purified polymer of a soluble conducting polymer, wherein the total metal content of the soluble conducting polymer is about 50 ppm or less.
First Solution
[0086] The first solution is adapted for dissolving the soluble conducting polymer and can comprise a first solvent system comprises one or more compounds in heterogeneous or homogeneous form.
[0087] Solvents for conducting polymers are known in the art and include organic solvents, aqueous solvents, and mixtures of solvents. In particular, ethers such as THF can be used. Solvents can be used which are used in ring opening metathesis polymerization reactions.
[0088] The first solution can be a solution which is taken from a polymer synthesis reaction including as needed one or more workup steps. If desired, the amount of solvent can be varied so for example the amount of solvent can be reduced by for example evaporation to concentrate the polymer before precipitation.
[0089] In particular, an acid work up step can be used to provide the first solution.
[0090] In some cases, the first solution may not be a true solution, but rather the polymer may form a dispersion which functions equivalently for purposes herein as a true solution and is considered herein as a true solution.
Soluble Conducting Polymer
[0091] Electrically conductive polymers, including soluble conducting polymers, are described in The Encyclopedia of Polymer Science and Engineering , Wiley, 1990, pages 298-300, including polyacetylene, poly(p-phenylene), poly(p-phenylene sulfide), polypyrrole, polythiophene, polyphenylene vinylene, and polyfluorenes, which is hereby incorporated by reference in its entirety. This reference also describes blending and copolymerization of polymers, including block copolymer formation. The soluble conducting polymer can be for example a heterocyclic polymer comprising polymerized rings, wherein a nitrogen or sulfur atom is in a ring as known in the art.
[0092] Polymeric semiconductors are described in, for example, “Organic Transistor Semiconductors” by Katz et al., Accounts of Chemical Research , vol. 34, no. 5, 2001, page 359 including pages 365-367, which is hereby incorporated by reference in its entirety.
[0093] Soluble conducting polymers are known in the art. In many cases, a conjugated backbone structure is present which is functionalized or derivatized with side groups to provide solubility. For example, provisional patent application Ser. No. 60/612,641 filed Sep. 24, 2004 to Williams et al. (“HETEROATOMIC REGIOREGULAR POLY (3-SUBSTITUTEDTHIOPHENES) FOR PHOTOVOLTAIC CELLS”) and U.S. regular application Ser. No. 11/234,373 filed Sep. 26, 2005 are hereby incorporated by reference in their entirety including the description of the polymers, the figures, and the claims.
[0094] In addition, provisional patent application Ser. No. 60/612,640 filed Sep. 24, 2004 to Williams et al. (“HETEROATOMIC REGIOREGULAR POLY(3-SUBSTITUTEDTHIOPHENES) FOR ELECTROLUMINESCENT DEVICES”), and U.S. regular Ser. No. 11/234,374 filed Sep. 26, 2005, are hereby incorporated by reference in their entirety including the description of the polymers, the figures, and the claims.
[0095] Provisional patent application Ser. No. 60/628,202 filed Nov. 17, 2004 to Williams et al. (“HETEROATOMIC REGIOREGULAR POLY (3-SUBSTITUTEDTHIOPHENES) AS THIN FILM CONDUCTORS IN DIODES WHICH ARE NOT LIGHT EMITTING”) and U.S. regular application Ser. No. 11/274,918 filed Nov. 16, 2005 which are hereby incorporated by reference in their entirety including the description of the polymers, the figures, and the claims.
[0096] Synthetic methods, doping, and polymer characterization, including regioregular polythiophenes with side groups, is provided in, for example, U.S. Pat. Nos. 6,602,974 to McCullough et al. and 6,166,172 to McCullough et al., which are hereby incorporated by reference in their entirety. Additional description can be found in the article, “The Chemistry of Conducting Polythiophenes,” by Richard D. McCullough, Adv. Mater. 1998, 10, No. 2, pages 93-116, and references cited therein, which is hereby incorporated by reference in its entirety. Another reference which one skilled in the art can use is the Handbook of Conducting Polymers, 2 nd Ed. 1998, Chapter 9, by McCullough et al., “Regioregular, Head-to-Tail Coupled Poly(3-alkylthiophene) and its Derivatives,” pages 225-258, which is hereby incorporated by reference in its entirety. This reference also describes, in chapter 29, “Electroluminescence in Conjugated Polymers” at pages 823-846, which is hereby incorporated by reference in its entirety.
[0097] Polythiophenes are described, for example, in Roncali, J., Chem. Rev. 1992, 92, 711; Schopf et al., Polythiophenes. Electrically Conductive Polymers , Springer: Berlin, 1997.
[0098] Block copolymers are described in, for example, Block Copolymers, Overview and Critical Survey , by Noshay and McGrath, Academic Press, 1977. For example, this text describes A-B diblock copolymers (chapter 5), A-B-A triblock copolymers (chapter 6), and —(AB) n -multiblock copolymers (chapter 7), which can form the basis of block copolymer types in the present invention.
[0099] Additional block copolymers including polythiophenes are described in, for example, Francois et al., Synth. Met. 1995, 69, 463-466, which is incorporated by reference in its entirety; Yang et al., Macromolecules 1993, 26, 1188-1190; Widawski et al., Nature ( London ), vol. 369, Jun. 2, 1994, 387-389; Jenekhe et al., Science, 279, Mar. 20, 1998, 1903-1907; Wang et al., J. Am. Chem. Soc. 2000, 122, 6855-6861; Li et al., Macromolecules 1999, 32, 3034-3044; Hempenius et al., J. Am. Chem. Soc. 1998, 120, 2798-2804.
[0100] In one embodiment, the conducting polymer is a 3-substituted polythiophene. In another embodiment, the conducting polymer is a 3-alkyl or 3-alkoxy substituted polythiophene.
[0101] Polymers can be used which have narrow or broad molecular weight distributions, polydispersity index, such as for example 1.5 or less. Polymers can be prepared under living conditions which provide control over molecular weight. Weight average molecular weight can be for example about 5,000 to about 100,000 or about 5,000 to about 25,000.
[0102] In one embodiment, the purification method can comprise the step of preparing the conducting polymer with use of nickel and magnesium compounds.
[0103] In one embodiment, the purification method can comprise the step of preparing the conducting polymer with use of ring opening metathesis polymerization including grignard ring opening metathesis polymerization (GRIM).
[0104] In one embodiment, the purification method can comprise the step of preparing the conducting polymer by polymerization of a thiophene monomer.
[0105] If desired, at least two soluble conducting polymers, or mixtures thereof, can be used.
[0106] Polymers are generally used which are prepared with transition metals or metals generally or otherwise comprise undesired amounts of transition metals or metals generally including for example magnesium, nickel, palladium, and platinum.
Second Solution
[0107] The second solution can be adapted for polymer precipitation and can comprise a second solvent system. Solvents can be selected in which the polymer has little if any solubility and can be called non-solvents for the polymer or a nonsolvent in a precipitation context. Mixtures of non-solvents can be used. Solvents should be adapted to provide good solubility for the metal complexing agent. Alcohols such as methanol and ethanol can be used.
Metal Complexing Agent
[0108] The metal complexing agent is not particularly limited so long as it can dissolve in the second solvent system and bind with one or more metals in the polymer in need of purification. It can be a lower molecular weight compound, an oligomer, or a polymer. It can be a chelating compound comprising a plurality of binding groups such as two, three, four, five, or six binding groups. It can be a polymer having binding groups in the backbone or in the side group. The metal complexing agent can comprise carbon, hydrogen, and a heteroatom such as nitrogen or oxygen which provides polarity and Lewis base character. The metal complexing agent can provide for example coordinate bonding as is known in transition metal complexing.
[0109] In one embodiment, the metal complexing agent can be represented by:
[0000] X 1 —R—X 2
[0000] Wherein X 1 and X 2 can be the same or different and represent groups which can complex to metals. The spacer group R can help ensure that the two binding groups are in position to provide multiple binding to a single metal atom. For example, the R group can be a C2, C3, or C4 group. The R group can be further derivatized with groups such as alkyl such as methyl or ethyl. In one embodiment, X1 and X2 can be ═N(OH).
[0110] In one embodiment, for example, the metal complexing agent comprises a chelating compound with at least two binding groups. In one embodiment, the metal complexing agent comprises a chelating compound with at least two nitrogen binding groups. In one embodiment, the metal complexing agent comprises a chelating compound comprising at least two oxime groups. In one embodiment, the metal complexing agent comprises a glyoxime compound. In one embodiment, the metal complexing agent comprises dimethylglyoxime.
[0111] In one embodiment, the metal complexing agent comprises a crown ether. Crown ether can be for example 18-crown-6 ether or 15-crown-5 ether to complex with for example potassium or sodium respectively. The size of the ether ring can be adjusted to complex with a particular metal. Other crown ethers can be used such as for example 18-crown-6 or 12-crown-4, as well as cryptans and host-guest types of complexing agents.
[0112] In one embodiment, the metal complexing agent comprises a compound comprising a plurality of oxygen atoms.
[0113] The metal complexing agent can be an oligomer or polymer. In one embodiment, the complexing agent comprises a polymer comprising a nitrogen or oxygen atom. In one embodiment, the complexing agent comprises a polymer comprising a nitrogen atom in the side group. In one embodiment, the complexing agent comprises an acrylamide or pyridine functional group. Examples include poly(N-isopropyl acrylamide) (PNIPAM) and poly(N-vinyl pyridine). Another example is an carboxylic acid containing polymer such as poly(acrylic acid).
[0114] In one embodiment, the second solution comprises at least two metal complexing agents.
[0115] A mixture of metal complexing agents can be used. In some cases, one complexing agent can be selected for a first metal, whereas a second complexing agent can be used for a second metal, and on and one with additional metal complexing agents.
[0116] Simultaneous or sequential methods can be used with multiple complexing agents. Hence, the complexing agents can be mixed in one solvent system and all exposed to the polymer in one step. Or the polymer can be purified in a time sequential process of using multiple second solutions one at a time.
[0117] In another embodiment, the combining step mixing the first solution and the second solution is carried out only once to precipitate the conducting polymer before isolating the polymer.
[0118] In another embodiment, there is no two-phase separation step, liquid extraction step, or solid extraction step prior to isolating the polymer.
[0119] The amount or concentration of the complexing agent is not particularly limited so long as the metal impurity reduction to the desired level can be achieved. For example, one can consider how much of the complexing agent is the part that binds to the metal. For example, in one embodiment, the amount of the metal complexing agent is at least about 0.01 g/100 mL of second solution. For example, in one embodiment, the amount of the metal complexing agent is at least about 0.1 g/100 mL of second solution. In one embodiment, the amount of the metal complexing agent is at least about 0.5 g/100 mL of second solution. In one embodiment, the amount of the metal complexing agent is at least about 1.0 g/100 mL of second solution.
[0120] While the present embodiments are not to be limited by theory, FIGS. 1 and 2 help illustrate some reactions which may be relevant, particularly for polythiophene and regioregular polythiophene embodiments. In some cases, polythiophenes are prepared with use of nickel catalysts. In FIG. 1 , polymer is shown having nickel complex at one end and HCl is shown to cleave the nickel catalyst from the polymer chain. This can provide a polymer free from the metal at the end group. For example, the end groups can be H and Br. In FIG. 2 , the nickel complex then undergoes ligand exchange with the metal complexing agent.
[0121] Additional embodiments are provided:
[0000] 1) Complexing agents for nickel which form nickel complex soluble in ethanol and methanol include dimethyl glyoxime, Eriochrome black T, bidentate and tetradentate amines, bipyridine, and terpyridine;
2) Complexing agents for magnesium which form magnesium complex soluble in ethanol or methanol include crown ethers; aza cown ethers, and cryptands;
3) Complexing agents that form both nickel and magnesium complexes soluble in water include EDTA (ethylenediamine tetra-acetic acid), glycine, and nitriloacetic acid.
4) Complexing agents for iron removal (for example, from oxidative polymerization of 3-alkyl thiophene) include 1,10-phenanthroline, catechols and salicylic acid;
5) Polymeric complexing agents which are soluble in methanol and ethanol include poly(N-isopropyl acrylamide), poly(N-vinyl pyridine), and also polymeric complexing agents which are soluble in water include poly(acrylamide) and poly(vinyl alcohol).
[0000]
Complexing agent
Chemical formula
Dimethyl glyoxime
Eriochrome Black T
15-crown-5
EDTA
Glycine
Nitriloacetic acid
1,10 Phenanthroline
Catechol
Salycilic acid
[0122] One can select the amount of complexing agent to be in a large excess compared to the amounts of metal to be removed such as for example 3× excess or 10× excess.
[0123] The theoretical content of magnesium in polymer samples, before purification, can be for example about 10 wt. % to about 15 wt. %. After only conventional methanol extraction, the content of magnesium can be around 500-600 ppm. However, further cleaning with dimethyl glyoxime can reduce the magnesium content to about 150 ppm to about 200 ppm. Cleaning with 15-c-5 crown ether can reduce the magnesium content under the detection limit (less than 10 ppm).
[0124] The theoretical content of nickel in polymer, before purification, can be for example about 500 ppm to about 1,000 ppm (less nickel can be present when higher molecular weight polymers are designed). After only conventional methanol extraction, the content of nickel can be around 500 ppm to about 900 ppm (generally, only methanol extraction does not reduce much the nickel content). Cleaning with dimethyl glyoxime can reduce the nickel content under the detection limit (e.g., less than 10 ppm).
[0125] Magnesium salts can be more soluble in methanol and nickel salts can be much less soluble so that for a low nickel content, purification with a complexing agent is very important.
Adding Step
[0126] The polymer can be precipitated by adding the first solution to the second solution under experimental conditions such as temperature, concentration, stirring or agitation, and pour rate which facilitate precipitation of the polymer.
[0127] Particle size can be controlled to tailor the ease with which polymer can be isolated. For example, decreased particle size can result in more surface area and better purification for cleaning the polymer. However, this may make polymer isolation more difficult.
[0128] In one embodiment, the precipitation is performed only once.
Isolating Step
[0129] Methods known in the art can be used to isolate the polymer. These include for example filtration.
[0130] If desired, additional purification can be used such as extraction.
[0131] In one embodiment, there is no two-phase separation step, liquid extraction step, or solid extraction step prior to the isolating step.
Purified Polymer
[0132] Purification can be done faster according to the methods described herein. Larger amounts of polymer can be dissolved. The purified polymer can provide better solubility in organic solvents. As a result, for example, higher molecular weight polymers can be dissolved for a given solvent. The experimental conditions needed for solubilization can be much easier. Also, better analytical data can be obtained including for example mass spectral analysis such as MALDI-MS (matrix assisted laser desorption ionization).
[0133] The purified polymers can also provide better mobility and photovoltaic performance.
[0134] The purified polymer can be characterized to determine the metal content. In particular, contents of nickel and magnesium can be examined. Total metal content can be 50 ppm or less, or 40 ppm or less, or 30 ppm or less, or 20 ppm or less, or 10 ppm or less, or 1 ppm or less.
[0135] For example, in one embodiment, the isolated polymer comprises no residual ash in elemental analysis.
[0136] In another embodiment, the isolated polymer provides an ICP-MS nickel analysis of less than 1 ppm.
[0137] In another embodiment, the isolated polymer provides an ICP-MS magnesium analysis of less than 1 ppm.
[0138] In another embodiment, the isolated polymer provides an ICP-MS magnesium analysis and an ICP-MS nickel analysis both less than 1 ppm.
[0139] In another embodiment, the isolated polymer provides an ICP-MS nickel or magnesium analysis of less than 20 ppm.
[0140] In another embodiment, the isolated polymer provides an ICP-MS nickel or magnesium analysis of less than 10 ppm.
Applications and Devices
[0141] The purified polymers can show better optical and electrical properties. They can also provide better thermal and oxidative stability.
[0142] The polymers can be used for example in OLED, PLED, transistors, field effect transistors, photovoltaic cells, sensors, electrostatic dissipation coatings, and other devices for which conducting polymers have been used.
[0143] In particular, field effect transistors, hole injection layer and hole transport layer are important applications. Polymers having higher mobilities can be prepared.
[0144] Polymers can be formed into layers and used with electrodes and interlayers as known in the art.
[0145] Polymer blends can be prepared with other polymers.
WORKING EXAMPLES
[0146] Non-limiting working examples are also provided.
Working Example No. 1
Dimethylglyoxime
[0147] General Procedure for the Synthesis of Nickel Free Regioregular poly(3-hexylthiophene):
[0148] A dry 100 mL three-neck flask was flashed with nitrogen and was charged with 2,5-dibromo-3-hexylthiophene (9.8 g, 30 mmol) and anhydrous THF (300 mL). A 2M solution of t-butyl magnesium chloride (15 mL, 30 mmol) in diethyl ether (Et 2 O) was added via a syringe, and the reaction mixture was gently refluxed for 60 min. The reaction mixture was allowed to cool down to room temperature, at which time Ni(dppp)Cl 2 (0.3 g, 0.54 mmol) was added to the reaction mixture. The polymerization was allowed to proceed for 20 min at room temperature followed by quenching of the reaction mixture with 3 ml HCl (37% wt) and 10 ml ethanol. After 5 min of stirring the solution was poured into a beaker containing 3 g of dimethyl glyoxime dissolved in 200 ml ethanol. The reaction mixture containing the precipitated polymer was stirred for 2 hours at room temperature, followed by filtering through a thimble. The polymer collected in the thimble was purified by Soxhlet extraction with ethanol for 4-8 hrs. The polymer was dried for 24 hrs under vacuum. The polymer was characterized by 1H NMR, MALDI-TOF-MS, elemental analysis and ICP-MS. Elemental analysis indicated the absence of ash (ash results from inorganic impurities such as magnesium and nickel salts). ICP-MS analysis of the purified polymer indicates the absence of nickel (Ni<1 ppm) and a content of magnesium between 50-200 ppm.
[0000]
TABLE 1
Elemental analysis of regioregular poly(3-hexylthiophene) purified
only by methanol extraction (PHT-MeOH) and purified with
dimethylglyoxime (PHT-DMG)
Elem. Analysis
(C, H, S)
PHT-MeOH
PHT-DMG
C
70.93 (71.1)
70.73 (71.1)
H
8.32 (8.3)
8.34 (8.3)
S
18.89 (19.0)
18.17 (19.0)
Ash
1.1
none
[0000]
TABLE 2
Metal content of regioregular poly(3-hexylthiophene) purified
only by methanol extraction (PHT-MeOH) and purified with
dimethylglyoxime (PHT-DMG)
Metal (ppm)
PHT-MeOH
PHT-DMG
Ni*
747
Not detected
Mg*
539
182
*determined from ICP-MS analysis
Working Example No. 2
Crown Ether
[0149] General Procedure for the Synthesis of Nickel and Magnesium Free Regioregular poly(3-hexylthiophene):
[0150] A dry 100 mL three-neck flask was flashed with nitrogen and was charged with 2,5-dibromo-3-hexylthiophene (9.8 g, 30 mmol) and anhydrous THF (300 mL). A 2M solution of t-butyl magnesium chloride (15 mL, 30 mmol) in diethyl ether (Et 2 O) was added via a syringe, and the reaction mixture was gently refluxed for 60 min. The reaction mixture was allowed to cool down to room temperature, at which time Ni(dppp)Cl 2 (0.3 g, 0.54 mmol) was added to the reaction mixture. The polymerization was allowed to proceed for 20 min at room temperature followed by quenching of the reaction mixture with 3 ml HCl (37% wt) and 10 ml ethanol. After 5 min of stirring the solution was poured into a beaker containing 3 g of dimethyl glyoxime (complexing agent for nickel) and 3 ml of 15-crown-5 (complexing agent for magnesium) dissolved in 200 ml ethanol. The reaction mixture containing the precipitated polymer was stirred for 2 hours at room temperature, followed by filtering through a thimble. The polymer collected in the thimble was purified by Soxhlet extraction with ethanol for 4-8 hrs. The polymer was dried for 24 hrs under vacuum. The polymer was characterized by 1 H NMR, MALDI-TOF-MS, elemental analysis and ICP-MS. Elemental analysis indicated the absence of ash (ash results from inorganic impurities such as magnesium and nickel salts). ICP-MS analysis of the purified polymer indicates the absence of nickel and magnesium (Ni, Mg<1 ppm).
ICP-MS=Inductively Coupled Plasma Mass Spectrometry
Working Example No. 3
Polymer Complexing Agents
[0151]
[0000]
TABLE 3
ICP-MS of regioregular poly(3-hexylthiophene) upon purification
with poly(N-isopropylacrylamide)
Metal (ppm)
PHT-MeOH
PHT-PNIPAM
Ni
760
5
Mg
550
20 | Metal complexing agents are used to purify polymers including conducting polymers to provide very low metal content. The process comprises precipitating the polymer in solution into a solvent system comprising the metal complexing agent. Very low levels including undetectable levels of metals such as nickel and magnesium can be achieved. High purity polymers are used in electronics and photovoltaic applications. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY
[0001] The present application is related to and claims priority under 35 U.S.C. §119(a) to a Korean Patent Application filed in the Korean Intellectual Property Office on Aug. 24, 2010 and assigned Serial No. 10-2010-0081770, the contents of which are herein incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to a wireless communication system. More particularly, the present invention relates to an apparatus and method for managing an operation mode of a Mobile Station (MS) in a wireless communication system.
BACKGROUND OF THE INVENTION
[0003] In a wireless communication system, an MS can operate in a connected state and an idle state for the sake of reduction of power consumption and efficient management of a wireless resource of a Base Station (BS), after network entry. Here, the connected state includes a sleep mode and an active mode. For instance, in a case where the MS is in the active mode, the MS maintains at least one connection with the BS. At this time, the MS can make a transition to the sleep mode so as to decrease the power consumption.
[0004] In a case where the MS operates in the idle state, the MS is not registered to the BS, and operates in a Paging Available Interval (PAI) and a Paging Unavailable Interval (PUI). In this case, the MS monitors paging only in the PAI. Accordingly, in a case where a traffic that the BS will transmit to the MS operating in the idle state is generated, the BS performs paging as illustrated in FIG. 1 below.
[0005] FIG. 1 illustrates a procedure for performing paging to an MS that is in an idle state according to the conventional art.
[0006] As illustrated in FIG. 1 , in a case where an MS 110 operates in an idle state, the MS 110 monitors paging during a PAI. On the other hand, the MS 110 transmits/receives no signal during a PUI.
[0007] In a case where a BS 100 recognizes traffic generation for the MS 110 , if a PAI of the MS 110 arrives, the BS 100 performs paging ( 120 ) to the MS 110 . That is, the BS 100 waits during a PUI of the MS 110 .
[0008] The MS 110 performs a network reentry procedure ( 130 ) if paging to itself is detected during a PAI. On the other hand, the MS 110 enters a PUI if no paging to itself is detected during the PAI.
[0009] In a case where the MS 110 operates in the idle state as above, the wireless communication system generates a paging delay pending the paging to the MS 110 until before the PAI and a network reentry delay resulting from network reentry of the MS 110 .
[0010] A service for emergency such as a disaster requires a strict interactive response time of an MS. However, in a case where the MS using the emergency service operates in the idle state, there is a problem that the MS cannot meet the interactive response time required for the emergency service due to the paging delay, the network reentry delay and the like.
SUMMARY OF THE INVENTION
[0011] To address the above-discussed deficiencies of the prior art, it is a primary object to provide at least the advantages below. Accordingly, one aspect of the present disclosure is to provide an apparatus and method for reducing a response delay of a Mobile Station (MS) operating in an idle state in a wireless communication system.
[0012] Another aspect of the present disclosure is to provide an apparatus and method for managing an operation mode of an MS in a wireless communication system.
[0013] A further aspect of the present disclosure is to provide an apparatus and method for restricting an operation mode of an MS in a Base Station (BS) of a wireless communication system.
[0014] Yet another aspect of the present disclosure is to provide an apparatus and method for managing an operation mode to which an MS can make a transition through a negotiation between a BS and the MS in a wireless communication system.
[0015] Still another aspect of the present disclosure is to provide an apparatus and method for managing an operation mode to which an MS can make a transition through a Dynamic Service Addition/Change/Deletion (DSx) procedure in a BS of a wireless communication system.
[0016] Still another aspect of the present disclosure is to provide an apparatus and method for managing an operation mode to which an MS can make a transition through a registration procedure of the MS in a BS of a wireless communication system.
[0017] The above aspects are achieved by providing an apparatus and method for managing an operation mode of a mobile station in a wireless communication system.
[0018] According to one aspect of the present disclosure, a method for managing an operation mode of an MS that uses a service of a strict interactive response time in a BS of a wireless communication system is provided. The method includes determining a supportable operation mode of the MS considering at least one of a service type of the MS, an interactive response time required condition of the service, and a user profile of the MS, and sending the MS a control message including the supportable operation mode of the MS.
[0019] According to another aspect of the present disclosure, a method for controlling an operation mode in an MS of a wireless communication system is provided. The method includes determining, from a control message provided from the BS, a supportable operation mode of the MS determined from considering at least one of a service type of the MS, an interactive response time required condition of a service, and a user profile of the MS, and determining a supportable operation mode on the basis of the supportable operation mode of the MS.
[0020] According to a further aspect of the present disclosure, an apparatus for managing an operation mode of an MS that uses a service of a strict interactive response time in a BS of a wireless communication system is provided. The apparatus includes an operation mode manager and a transmitter. The operation mode manager determines a supportable operation mode of the MS considering at least one of a service type of the MS, an interactive response time required condition of the service, and a user profile of the MS. The transmitter sends the MS a control message including the supportable operation mode of the MS.
[0021] According to a yet another aspect of the present disclosure, an apparatus for controlling an operation mode in an MS of a wireless communication system is provided. The apparatus includes a receiver and a controller. The receiver receives a control message from a BS. The controller determines the MS supportable operation mode based on a supportable operation mode of the MS determined considering at least one of a service type of the MS, an interactive response time required condition of a service, and a user profile of the MS in the control message provided from the BS through the receiver.
[0022] Before undertaking the DETAILED DESCRIPTION OF THE INVENTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
[0024] FIG. 1 illustrates a procedure for performing paging to a Mobile Station (MS) that is in an idle state according to the conventional art;
[0025] FIG. 2 is a ladder diagram illustrating a procedure for restricting an operation mode of an MS using a Dynamic Service Addition (DSA) message in a wireless communication system according to the present disclosure;
[0026] FIG. 3 illustrates a process for restricting an operation mode of an MS using a DSA message in a Base Station (BS) according to the present disclosure;
[0027] FIG. 4 illustrates a process for determining operation mode information through a DSA message in an MS according to the present disclosure;
[0028] FIG. 5 is a ladder diagram illustrating a procedure for restricting an operation mode of an MS using a registration message in a wireless communication system according to the present disclosure;
[0029] FIG. 6 illustrates a process for restricting an operation mode of an MS using a registration message in a BS according to the present disclosure;
[0030] FIG. 7 illustrates a process for determining operation mode information through a registration message in an MS according to the present disclosure;
[0031] FIG. 8 is a block diagram illustrating a construction of a BS according to the present disclosure; and
[0032] FIG. 9 is a block diagram illustrating a construction of an MS according to the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIGS. 2 through 9 , discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged wireless communication system. Embodiments of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail. Terms described below, which are defined considering functions in the present invention, can be different depending on user and operator's intention or practice. Therefore, the terms should be defined based on the disclosure throughout this specification. Preferred embodiments of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail. And, terms described below, which are defined considering functions in the present invention, can be different depending on user and operator's intention or practice. Therefore, the terms should be defined based on the disclosure throughout this specification.
[0034] Below, exemplary embodiments of the present disclosure provide technology for restricting an operation mode of a Mobile Station (MS) in a wireless communication system.
[0035] Below, exemplary embodiments of the present disclosure provide technology for restricting an operation mode of an MS according to an interactive response time of a service having a strict interactive response time required condition in a wireless communication system.
[0036] The following description is made, for example, for a wireless communication system defined in the Institute of Electrical and Electronics Engineers (IEEE) 802.16m standard. However, the present disclosure is also applicable to wireless communication systems defined in other standards.
[0037] As illustrated in FIG. 2 below, a Base Station (BS) and an MS of the wireless communication system can negotiate an operation mode of the MS through a Dynamic Service Addition/Change/Deletion (DSx) procedure. Here, the DSx procedure includes a process in which the BS and the MS exchange a DSx message with each other for service addition/change/deletion.
[0038] FIG. 2 illustrates a procedure for restricting an operation mode of an MS using a Dynamic Service Addition (DSA) message in a wireless communication system according to the present disclosure. In the following description, a BS 210 represents an Access Service Network (ASN) that includes a BS and an Access Service Network-GateWay (ASN-GW).
[0039] As illustrated in FIG. 2 , an MS 200 performs initial network entry through a BS 210 (step 221 ).
[0040] After the initial network entry of the MS 200 is completed, the MS 200 and BS 210 generate a service flow (step 223 ). For example, the MS 200 and BS 210 generate an initial/pre-provisioned service flow.
[0041] The MS 200 performs upper signaling with an upper network entity through the generated service flow (step 225 ). For example, the MS 200 initiates an application program for upper signaling and performs the upper signaling with the upper network entity through the BS 210 . Here, the upper network entity includes an application server, and the upper signaling includes Session Initialization Protocol (SIP) protocol signaling.
[0042] The BS 210 determines a service type of the MS 200 and an interactive response time required condition of a service using an upper signaling message provided from the upper network entity. For example, the BS 210 determines an operation mode supportable by the MS 200 in consideration of the service type of the MS 200 and the interactive response time required condition of the service.
[0043] After that, the BS 210 generates a DSA request message to establish a connection for application data transmission/reception. Here, the DSA request message includes operation mode information supportable by the MS 200 in a form of Table 1 below.
[0000]
TABLE 1
Attributes/Array
Size
M/O
of attributes
(bits)
Value/Note
Conditions
0
AMS Operation
2
Bit 0: Sleep mode support
Mode Supported
Bit 1: Idle mode support
A bit value of 0 indicates
“not supported” while 1
indicates “supported.”
[0044] In Table 1 above, in an example where the BS 210 restricts idle state transition of the MS 200 , the supportable operation mode information of the MS 200 is set to “0b10”. In contrast, in an example where the BS 210 restricts sleep mode transition of the MS 200 and permits the idle state transition of the MS 200 , the supportable operation mode information of the MS 200 is set to “0b01”.
[0045] The BS 210 sends the MS 200 the DSA request message including the operation mode information supportable by the MS 200 (step 227 ).
[0046] The MS 200 determines the supportable operation mode information of the MS 200 included in the DSA request message. At this time, the MS 200 determines an operation mode that the MS 200 will support itself based on the supportable operation mode information of the MS 200 included in the DSA request message. For another example, the MS 200 may determine whether to accept the supportable operation mode information of the MS 200 included in the DSA request message.
[0047] After that, the MS 200 sends the BS 210 a DSA response message including the MS's 200 supportable operation mode information (step 229 ). For example, the MS 200 transmits the MS's 200 determining operation mode information to the BS 210 using the DSA response message, based on the supportable operation mode information of the MS 200 included in the DSA request message. For another example, the MS 200 may transmit an acceptance or non-acceptance of the supportable operation mode information of the MS 200 included in the DSA request message to the BS 210 , using the DSA response message.
[0048] If the DSA response message is received, the BS 210 sets a packet classification rule, and sends a DSA ACKnowledgement (ACK) message to the MS 200 (step 231 ).
[0049] Next, the MS 200 and BS 210 perform a service (step 233 ). At this time, the MS 200 can perform a state transition within a supportable operation mode determined through a negotiation with the BS 210 .
[0050] In an example where the MS 200 or the BS 210 makes a request for application service termination in course of the service performance, the MS 200 and BS 210 determine whether to terminate the service performance between the MS 200 and the BS 210 through the upper signaling with the upper network entity.
[0051] In an example where the MS 200 and BS 210 determine to terminate the service performance, the BS 210 determines an operation mode that is supportable by the MS 200 after service termination.
[0052] After that, the BS 210 sends the MS 200 a DSD request message including operation mode information that is supportable by the MS 200 after service termination (step 235 ).
[0053] The MS 200 determines, in the DSD request message, the operation mode information that is supportable by the MS 200 after the service termination. At this time, the MS 200 determines an operation mode that the MS 200 will support the MS 200 based on the operation mode information supportable by the MS 200 after the service termination included in the DSD request message. For another example, the MS 200 may determine whether to accept the operation mode information supportable by the MS 200 after the service termination included in the DSD request message.
[0054] Next, the MS 200 sends the BS 210 a DSD response message including the MS's 200 supportable operation mode information (step 237 ). For example, the MS 200 transmits the MS's 200 determining operation mode information to the BS 210 using the DSD response message, based on the supportable operation mode information of the MS 200 included in the DSD request message. For another example, the MS 200 may transmit an acceptance or non-acceptance of the supportable operation mode information of the MS 200 included in the DSD request message to the BS 210 , using the DSD response message.
[0055] The BS 210 sends the MS 200 a DSD ACK message in response to the DSD response message (step 239 ).
[0056] In an example where the DSD ACK message is received, the MS 200 can perform a state transition within the supportable operation mode determined through the negotiation with the BS 210 .
[0057] As described above, an MS 200 and a BS 210 negotiate a supportable operation mode using a DSx message. At this time, in an example where the MS 200 provides a Push To Talk (PTT) service, the MS 200 and BS 210 generate or release a service flow for the PTT service through a DSx procedure. At this time, when the MS 200 and BS 210 generate and release the service flow for the PTT service, the MS 200 and BS 210 can negotiate an operation mode supportable by the MS 200 . Here, the PTT service includes a service for emergency.
[0058] FIG. 3 illustrates a procedure for restricting an operation mode of an MS using a DSA message in a BS according to the present disclosure. In the following description, it is assumed to provide a PTT service to the MS. However, it is identically applicable even to an example of providing other service sensitive to a delay to the MS.
[0059] Referring to FIG. 3 , in step 301 , the BS performs an initial network entry procedure of an MS. For example, the BS performs a ranging procedure, an authentication procedure, a registration procedure, and a capability negotiation procedure with the MS to complete the initial network entry procedure of the MS.
[0060] After initial network entry of the MS, the BS proceeds to step 303 and transmits/receives a signal for upper signaling between the MS and an upper network entity. For example, the BS generates a service flow with the MS after the initial network entry of the MS. And then, the BS controls such that the MS and the upper network entity perform the upper signaling through the generated service flow.
[0061] Next, the BS proceeds to step 305 and determines a supportable operation mode of the MS using an upper signaling message provided from the upper network entity. For example, the BS determines whether to generate a new service flow/connection with the MS and, if determining to generate the new service flow/connection with the MS, the BS determines an operation mode supportable by the MS considering a service type of the MS or an interactive response time required condition of a service. Here, the service type or the interactive response time required condition is determined using the upper signaling message. In an example where a service newly established with the MS is a service sensitive to an interactive response delay of the MS such as a PTT service, the BS does not permit an idle state transition of the MS. On the other hand, in an example where the BS manages the idle state transition of the MS for the purpose of PTT service capability increment, the BS may restrict a sleep mode transition of the MS, and permit the idle state transition of the MS.
[0062] After determining the supportable operation mode of the MS, the BS proceeds to step 307 and restricts the supportable operation mode of the MS using a DSA message. For instance, the BS sends the MS a DSA request message including the supportable operation mode information of the MS determined in step 305 . And then, the BS recognizes supportable operation mode information of the MS included in a DSA response message provided from the MS as the supportable operation mode of the MS while a service flow/connection newly generated through the DSA procedure is kept.
[0063] After restricting the supportable operation mode of the MS, the BS proceeds to step 309 and provides an application service to the MS through the service flow/connection generated through the DSA procedure. Here, the application service includes application services sensitive to a delay of an interactive response time of an MS such as a PTT service.
[0064] Next, the BS proceeds to step 311 and determines whether to terminate the application service with the MS. For example, in an example where the MS or the BS makes a request for application service termination in course of application service provision, the MS and BS determine whether to terminate application service performance through upper signaling with the upper network entity.
[0065] In an example where the MS and BS determine not to terminate the application service, the BS returns to step 309 and provides the application service to the MS.
[0066] On the other hand, in an example where the MS and BS determine to terminate the application service, the BS proceeds to step 313 and determines an operation mode supportable by the MS after application service termination.
[0067] After determining the operation mode supportable by the MS after the application service termination, the BS proceeds to step 315 and restricts the supportable operation mode of the MS using a DSD message. For instance, the BS sends the MS a DSD request message including the supportable operation mode information of the MS determined in step 313 . And then, the BS recognizes supportable operation mode information of the MS included in a DSD response message provided from the MS as the operation mode supportable by the MS after the application service termination.
[0068] After that, the BS terminates the algorithm according to the present disclosure.
[0069] FIG. 4 illustrates a procedure for determining operation mode information through a DSA message in an MS according to the present disclosure.
[0070] Referring to FIG. 4 , in step 401 , the MS performs an initial network entry procedure through a BS. For example, the MS performs a ranging procedure, an authentication procedure, a registration procedure, and a capability negotiation procedure with the BS to complete the initial network entry procedure.
[0071] After that, the MS proceeds to step 403 and initiates an application program for upper signaling. For instance, after completing the initial network entry, the MS generates a service flow with the BS. And then, the MS initiates the application program for the upper signaling.
[0072] After initiating the application program, the MS proceeds to step 405 and performs upper signaling with an upper network entity through the BS. Here, the upper network entity includes an application server, and the upper signaling includes SIP protocol signaling.
[0073] Next, the MS proceeds to step 407 and determines supportable operation mode information through a DSA message for generating a new service flow/connection with the BS. For example, the MS determines the MS's supportable operation mode information included in a DSA request message provided from the BS. And then, the MS determines the MS's own supportable operation mode based on the MS's supportable operation mode information included in the DSA request message. At this time, the MS transmits the MS's determining supportable operation mode information to the BS through a DSA response message. For another example, the MS may recognize the MS's supportable operation mode information included in the DSA request message as the MS's supportable operation mode information.
[0074] After determining the supportable operation mode information, the MS proceeds to step 409 and receives an application service from the BS through the service flow/connection generated through the DSA procedure. At this time, the MS can perform a state transition within the supportable operation mode determined in step 407 .
[0075] Next, the MS proceeds to step 411 and determines whether to terminate the application service with the BS. For example, the MS or the BS makes a request for application service termination in course of application service provision; the MS and BS determine whether to terminate application service performance through upper signaling with the upper network entity.
[0076] In an example where the MS and BS determine not to terminate the application service in step 411 , the MS returns to step 409 and receives the application service from the BS.
[0077] In contrast, in an example where the MS and BS determine to terminate the application service in step 411 , the MS proceeds to step 413 and performs upper signaling for the application service termination with the upper network entity through the BS.
[0078] After that, the MS proceeds to step 415 and determines an operation mode supportable after application service termination. For example, the MS determines the MS's supportable operation mode information included in a DSD request message provided from the BS. And then, the MS determines the MS's supportable operation mode based on the MS's supportable operation mode information included in the DSD request message. At this time, the MS transmits the MS's determining supportable operation mode information to the BS through a DSD response message. For another example, the MS may recognize the MS's supportable operation mode information included in the DSD request message as the MS's supportable operation mode information.
[0079] Next, the MS terminates the algorithm according to the present disclosure.
[0080] In the aforementioned example, an MS and a BS restrict a supportable operation mode of the MS through a DSx procedure.
[0081] In another example, an MS and a BS may restrict a supportable operation mode of the MS in an initial network entry process of the MS. At this time, the MS and BS may restrict the supportable operation mode of the MS through a registration procedure as illustrated in FIG. 5 below.
[0082] FIG. 5 illustrates a procedure for restricting an operation mode of an MS using a registration message in a wireless communication system according to the present disclosure. In the following description, a BS 510 represents an ASN that includes a BS and an ASN-GW.
[0083] As illustrated in FIG. 5 , an MS 500 performs initial network entry through a BS 510 . For example, the MS 500 and the BS 510 perform a ranging procedure, an authentication procedure, a registration procedure, and a capability negotiation procedure for the sake of network entry of the MS 500 . The BS 510 acquires a user profile for the MS 500 from an Authentication, Authorization and Accounting (AAA) server 520 through the authentication procedure (step 531 ). Here, the user profile includes a user identity, user's service subscription information, user state information and the like.
[0084] Next, the MS 500 and the BS 510 negotiate a supportable operation mode of the MS 500 through the registration procedure (step 533 ). For instance, the MS 500 sends a registration request message to the BS 510 . The BS 510 determines the supportable operation mode of the MS 500 considering the user profile. And then, the BS 510 sends the MS 500 a registration response message including the MS's determining supportable operation mode information of the MS 500 .
[0085] For another example, the MS 500 sends the BS 510 a registration request message including the MS's determining supportable operation mode information. The BS 510 determines a supportable operation mode of the MS 500 considering the supportable operation mode of the MS 500 determined in the registration request message and the user profile. And then, the BS 510 sends the MS 500 a registration response message including the MS's determining supportable operation mode information of the MS 500 .
[0086] If a network entry procedure with the BS 510 is completed, the MS 500 performs upper signaling through the BS 510 (step 535 ). For example, after the initial network entry of the MS 500 is completed, the MS 500 and BS 510 generate an initial/pre-provisioned service flow, and initiate an application program for upper signaling. And then, the MS 500 performs upper signaling such as SIP protocol signaling, with an upper network entity such as an application server through the BS 510 .
[0087] In an example where the BS 510 determines to generate a new service flow/connection with the MS 500 , the BS 510 performs a DSA procedure with the MS 500 (step 537 ). For example, the BS 510 sends a DSA request message to the MS 500 . In response to the DSA request message, the MS 500 sends a DSA response message to the BS 510 . In response to the DSA response message, the BS 510 sends the MS 500 a DSA ACK message to generate a new service flow/connection.
[0088] After generating the new service flow/connection through the DSA procedure, the BS 510 sends an ACK message for upper signaling to the MS 500 (step 539 ).
[0089] Next, the MS 500 and BS 510 perform a service (step 541 ). At this time, the MS 500 can perform a state transition within the supportable operation mode determined through the negotiation with the BS 510 .
[0090] As described above, an MS 500 and a BS 510 negotiate a supportable operation mode of the MS 500 using a registration request/response message. At this time, the registration request/response message includes supportable operation mode information of the MS 500 in a form of Table 1 above.
[0091] FIG. 6 illustrates a procedure for restricting an operation mode of an MS using a registration message in a BS according to the present disclosure. In the following description, it is assumed that a supportable operation mode of the MS is determined in the BS.
[0092] Referring to FIG. 6 , in step 601 , the BS performs an authentication procedure of an MS. At this time, the BS acquires a user profile for the MS from an AAA server through the authentication procedure of the MS. Here, the user profile includes a user identity, user's service subscription information, user state information and the like.
[0093] After that, the BS proceeds to step 603 and determines a supportable operation mode of the MS according to a service type of the MS or a service required condition of the MS, which is included in the user profile. For example, in an example where a service newly established with the MS is a service sensitive to an interactive response delay of the MS such as a PTT service, the BS does not permit an idle state transition of the MS. For another example, in an example where the BS manages the idle state transition of the MS for the purpose of P a service capability increment, the BS may restrict a sleep mode transition of the MS, and permit the idle state transition of the MS.
[0094] After determining the supportable operation mode of the MS in step 603 , the BS proceeds to step 605 and restricts the supportable operation mode of the MS using a registration message. For example, after the authentication procedure is completed, the MS sends the BS a registration request message. The BS sends the MS a registration response message including the supportable operation mode information of the MS determined in step 603 . At this time, the registration response message includes the supportable operation mode information of the MS in a form of Table 1 above.
[0095] After restricting the supportable operation mode of the MS in step 605 , the BS proceeds to step 607 and transmits/receives a signal for upper signaling between the MS and an upper network entity. For example, after initial network entry of the MS, the BS generates an initial/pre-provisioned service flow with the MS. And then, the BS controls such that the MS and the upper network entity perform upper signaling through the generated service flow.
[0096] Next, the BS proceeds to step 609 and performs a DSA procedure with the MS to generate a new service flow/connection. For instance, the BS determines whether to generate a new service flow/connection with the MS and, if determining to generate the new service flow/connection with the MS, the BS generates a new service flow/connection through the DSA procedure with the MS.
[0097] After generating the new service flow/connection in step 609 , the BS proceeds to step 611 and provides an application service to the MS through the service flow/connection generated through the DSA procedure.
[0098] After that, the BS terminates the algorithm according to the present disclosure.
[0099] FIG. 7 illustrates a procedure for determining operation mode information through a registration message in an MS according to the present disclosure. In the following description, it is assumed that a supportable operation mode of the MS is determined in a BS.
[0100] Referring to FIG. 7 , in step 701 , the MS determines operation mode information through a registration message. For example, after performing an authentication procedure with a BS for initial network entry, the MS sends a registration request message to the BS. And then, the MS determines supportable operation mode information in a registration response message provided from the BS.
[0101] After that, the MS proceeds to step 703 and initiates an application program for upper signaling. For example, after the initial network entry is completed, the MS generates an initial/pre-provisioned service flow with the BS. And then, the MS initiates the application program for upper signaling.
[0102] After initiating the application program, the MS proceeds to step 705 and performs upper signaling with an upper network entity through the BS. Here, the upper network entity includes an application server, and the upper signaling includes SIP protocol signaling.
[0103] Next, the MS proceeds to step 707 and performs a DSA procedure for the sake of generation of a new service flow/connection with the BS.
[0104] After generating the new service flow/connection through the DSA procedure, the MS proceeds to step 709 and receives an application service from the BS through the service flow/connection generated through the DSA procedure. At this time, the MS can perform a state transition within the supportable operation mode determined in step 701 .
[0105] Next, the MS terminates the algorithm according to the present disclosure.
[0106] In the aforementioned example, after performing an authentication procedure with a BS, an MS sends a registration request message to the BS. In response to the registration request message, the BS sends the MS a registration response message including supportable operation mode information of the MS determined using a user profile of the MS.
[0107] In another example, an MS sends the BS a registration request message including the MS's determining supportable operation mode information. In this example, the BS determines a supportable operation mode of the MS considering the supportable operation mode of the MS determined in the registration request message and the user profile. And then, the BS sends the MS a registration response message including the MS's determining supportable operation mode information of the MS.
[0108] FIG. 8 illustrates a construction of a BS according to the present disclosure.
[0109] As illustrated in FIG. 8 , the BS includes a duplexer 800 , a receiver 810 , a message processor 820 , a controller 830 , an operation mode manager 840 , a message generator 850 , and a transmitter 860 .
[0110] The duplexer 800 transmits a transmit signal provided from the transmitter 860 through an antenna according to a duplexing scheme, and provides a receive signal from the antenna to the receiver 810 .
[0111] The receiver 810 converts a Radio Frequency (RF) signal provided from the duplexer 800 into a baseband signal for demodulation. The receiver 810 can include an RF processing block, a demodulation block, a channel decoding block and the like. For example, the RF processing block converts an RF signal provided from the duplexer 800 into a baseband signal. The demodulation block is composed of a Fast Fourier Transform (FFT) operator for extracting data loaded on each subcarrier from a signal provided from the RF processing block and the like. The channel decoding block is composed of a demodulator, a de-interleaver, a channel decoder and the like.
[0112] The message processor 820 extracts a control message from a receive signal provided from the receiver 810 and transmits the control message to the controller 830 . For instance, the message processor 820 extracts a DSA response message or a DSD response message from the receive signal and transmits the extracted message to the controller 830 . For another instance, the message processor 820 extracts a registration request message from the receive signal and sends the extracted message to the controller 830 .
[0113] The controller 830 controls a general operation of the BS.
[0114] The controller 830 restricts an operation mode of the MS using supportable operation mode information of an MS determined in the operation mode manager 840 . For example, as illustrated in FIG. 3 , the controller 830 controls to transmit the supportable operation mode information of the MS determined in the operation mode manager 840 to the MS through a DSx request message. For another example, as illustrated in FIG. 6 , the controller 830 controls to transmit the supportable operation mode information of the MS determined in the operation mode manager 840 to the MS through a registration response message.
[0115] The operation mode manager 840 determines a supportable operation mode of an MS. For example, in an example where a service newly established with the MS is sensitive to an interactive response delay of the MS such as a PTT service, the operation mode manager 840 does not permit an idle state transition of the MS. For another example, in an example where the BS manages the idle state transition of the MS for the purpose of PTT service capability increment, the operation mode manager 840 may restrict a sleep mode transition of the MS, and permit the idle state transition of the MS.
[0116] The message generator 850 generates a control message to be sent to an MS according to the control of the controller 830 . For instance, the message generator 850 generates a DSx request message including supportable operation mode information of an MS determined in the operation mode manager 840 according to the control of the controller 830 . For another instance, the message generator 850 generates a registration response message including supportable operation mode information of an MS determined in the operation mode manager 840 according to the control of the controller 830 .
[0117] The transmitter 860 encodes data and control message to be transmitted to an MS, converts the data and control message into an RF signal, and transmits the RF signal to the duplexer 800 . For instance, the transmitter 860 can include a channel coding block, a modulation block, an RF processing block and the like. Here, the channel coding block is composed of a modulator, an interleaver, a channel encoder and the like. The modulation block is composed of an Inverse Fast Fourier Transform (IFFT) operator for mapping a signal provided from the channel coding block to each subcarrier and the like. The RF processing block converts a baseband signal provided from the modulation block into an RF signal and outputs the RF signal to the duplexer 800 .
[0118] In the aforementioned construction, the controller 830 , a protocol controller, can perform a function of the operation mode manager 840 . These are separately constructed in order to distinguish and describe respective functions in the present disclosure. Thus, in an actual realization, construction can be such that all or some of the functions are processed in the controller 830 .
[0119] FIG. 9 illustrates a construction of an MS according to the present disclosure.
[0120] As illustrated in FIG. 9 , the BS includes a duplexer 900 , a receiver 910 , a message processor 920 , a controller 930 , a message generator 940 , and a transmitter 950 .
[0121] The duplexer 900 transmits a transmit signal provided from the transmitter 950 through an antenna according to a duplexing scheme, and provides a receive signal from the antenna to the receiver 910 .
[0122] The receiver 910 converts a Radio Frequency (RF) signal provided from the duplexer 900 into a baseband signal for demodulation. The receiver 910 can include an RF processing block, a demodulation block, a channel decoding block and the like. For example, the RF processing block converts an RF signal provided from the duplexer 900 into a baseband signal. The demodulation block is composed of a Fast Fourier Transform (FFT) operator for extracting data loaded on each subcarrier from a signal provided from the RF processing block and the like. The channel decoding block is composed of a demodulator, a de-interleaver, a channel decoder and the like.
[0123] The message processor 920 extracts a control message from a receive signal provided from the receiver 910 and transmits the control message to the controller 930 . For instance, the message processor 920 extracts a DSA request message or a DSD request message from the receive signal and transmits the extracted message to the controller 930 . For another instance, the message processor 920 extracts a registration response message from the receive signal and sends the extracted message to the controller 930 .
[0124] The controller 930 controls a general operation of the MS. For example, as illustrated in FIG. 4 , the controller 930 determines the MS's supportable operation mode information according to supportable operation mode information included in a DSx request message provided from the BS. For another example, as illustrated in FIG. 7 , the controller 930 determines the MS's supportable operation mode information according to supportable operation mode information included in a registration response message provided from the BS.
[0125] The message generator 940 generates a control message to be sent to a BS according to the control of the controller 930 . For instance, the message generator 940 generates a DSx response message including the MS's determining supportable operation mode information according to the control of the controller 930 . For another instance, the message generator 940 generates a registration request message including the MS's determining supportable operation mode information according to the control of the controller 930 .
[0126] The transmitter 950 encodes data and control message to be transmitted to a BS, converts the data and control message into an RF signal, and transmits the RF signal to the duplexer 900 . For instance, the transmitter 950 can include a channel coding block, a modulation block, an RF processing block and the like. Here, the channel coding block is composed of a modulator, an interleaver, a channel encoder and the like. The modulation block is composed of an IFFT operator for mapping a signal provided from the channel coding block to each subcarrier and the like. The RF processing block converts a baseband signal provided from the modulation block into an RF signal and outputs the RF signal to the duplexer 900 .
[0127] As described above, exemplary embodiments of the present disclosure have an advantage of, by restricting an operation mode to which an MS can make a transition through a negotiation between a BS and the MS, being capable of reducing a delay of an operation mode transition of the MS and smoothly providing an emergency service requiring a strict interactive response time in a wireless communication system.
[0128] While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | An apparatus and method manage an operation mode of a mobile station in a wireless communication system. Here, a method for managing an operation mode of a Mobile Station (MS) that uses a service of a strict interactive response time in a Base Station (BS) of a wireless communication system includes determining a supportable operation mode of the MS considering at least one of a service type of the MS, an interactive response time required condition of the service, and a user profile of the MS, and sending the MS a control message including the supportable operation mode of the MS. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] Benefit of U.S. Provisional Application for Patent Ser. No. 61/330,074 filed on Apr. 30, 2010, which is incorporated herein by reference, is hereby claimed.
FIELD OF THE INVENTION
[0002] The present invention relates to power cord systems, and is more particularly concerned with a 360-degree freedom electric cord system for use with a push/pull-type electric machine displaceable on a surface by a user/operator that contains and manages automatic extension and retraction of the electric cord/cable supplying power thereto. The 360-degree freedom electric cord system, mounted on the electric machine, allows the power cord to continuously power the electric machine while freeing up the operator's hands to entirely focus on the operation of the machine and includes a self-retracting spool to automatically extend and rewind the power cord and continuously keeps tension therein during the displacement, in any direction, of the electric machine, according to the operator's desirable intent.
[0003] More specifically, the invention of the 360-degree freedom electric cord system (device) is an electrical retractable cord (cable) reel device system planned, developed and intended to be installed (by the operator) onto existing motorized (or mobile) push machines or installed permanently by the manufacturer on or into newly manufactured motorized (or mobile) or used push machines. The 360-degree freedom electric cord system (device) provides an electric power cord (cable) extension for (any) electric user push (motorized) machines which are directed by the operator's desired intent, i.e. forwards (push mode), backwards (pull mode), straight, right, left, square, rectangle, circle 360 degrees, spiral, octave, etc.
BACKGROUND OF THE INVENTION
[0004] Most electric machines displaceable by a user on a surface, either push/pull-type (pushed or pulled by a user) or being motorized for self propulsion or the like, which are steered by a user, require an electric cord or cable extension to supply power to the machine for operation thereof. Although these electrical machines, such as lawnmowers, floor cleaners, carpet cleaners, vacuum cleaners, garden & yarn machines, snow blowers, floor working (as industrial scrubbers) and floor finishing machines or the like, are less polluting than corresponding fuel consuming ones or even than battery-powered ones, they have the disadvantage of having an electric cord or wire to supply power thereto, and it is time consuming and cumbersome to take care of the electric wire following the machine by continuously watching and/or holding it to ensure it does not get damaged or stuck to an obstacle lying on the surface.
[0005] Accordingly, there is a need for an improved electric cord device system.
SUMMARY OF THE INVENTION
[0006] It is therefore a general object of the present invention to provide an improved electric cord device system.
[0007] An advantage of the present invention is that the electric cord device allows a user to freely displace or steer a push/pull-type electric machine on a surface without releasing him from continuously handling the power supply electric cord or cable from side to side while the machine operates and moves in any direction, thus saving operating time without having to stop the machine.
[0008] Another advantage of the present invention is that the cord device allows a 360-degree freedom for the steering (displacement) of the electric machine, with a continuously self-adjusting cord length, in generally straight line, between the electric machine and the region adjacent the power wall outlet, thereby freeing the attention and the hands of the user during operation of the machine.
[0009] A further advantage of the present invention is that the cord device keeps the electric cord or cable into a natural position/orientation under tension above the surface and obstacles thereon without stopping the machine operation, thereby ensuring user safety, and also prevents twisting of the electric cord.
[0010] Still another advantage of the present invention is that the cord device has the electric cord wound around a self-retractable spool to ensure the tension in the electric cord, as well as the automatic extension and retraction thereof while the working electric machine is operating and being displaced on the surface, with the power cord unwinding from the spool when the machine is displaced away from fixed structure and its power outlet, and, reversely, with the power cord rewinding on the spool when the machine approaches the fixed structure, thus enabling any type of movement of the electric machine during operation.
[0011] Another advantage of the present invention is that the cord device can be adapted to any push/pull-type electric machine, and mounted either on the machine (as a retrofit), via a stand holder or directly secured to the machine, or inside the machine, installed by the machine manufacturer.
[0012] A further advantage of the present invention is that the cord device includes a cord holder member that can be adapted to releasably mount on different rigid structures, depending on the location, as in restricted areas, built-up areas, indoors, outdoors, outside or inside of the structure, open area, hallway, corridor with lower ceiling, in/out of the building, or the like, and the use of the electric machine carrying the device.
[0013] Yet another advantage of the present invention is that the cord device can be configured for indoor and/or outdoor use, have models adapted for different gauge extension cords used on different residential, commercial or industrial push/pull-type electric machines.
[0014] Still a further advantage of the present invention is that the cord device can be serviceable as a standard electric retractable extension cord reel, for other electric hand tools or the like electrical devices, when on or in the electric machine, and can also be serviceable when off a machine, and being adaptable to mount on the ground, on the wall or hanging from a rigid structure in such cases.
[0015] Still another advantage of the present invention is that the cord device prevents accidental unplugging of the power cord from the wall power outlet because of the cord holder member.
[0016] According to an aspect of the present invention, there is provided a 360-degree freedom electric cord device for receiving an electric cord and for using with a push/pull-type electric machine displaceable by a user on a surface, said device comprising:
a housing member mountable on a displaceable electric machine and having a self-retracting spool member for housing a first end portion of an electric cord connectable to the electric machine; an elongated post member defining a post member axis and first and second post member ends longitudinally opposed from one another, said first post member end connecting to the housing member, said post member having a through bore extending therealong between said first and second post member ends for receiving a central portion of the electric cord therein, said second post member end having a cord guiding member for allowing the electric cord to extend substantially radially therefrom and to freely rotate within a 360-degree span angle about the post member axis; and a cord holder member connectable to a structure for supporting a second end portion of the electric cord adjacent thereto and away from said post member, said cord holder member including a cord state holder mechanism connectable to the electric cord for preventing torsion twisting thereof.
[0020] Typically, the post member is adjustable in length.
[0021] In one embodiment, the cord guiding member is an outwardly enlarging diameter of said through bore at said second post member end in a direction extending away from said first post member end.
[0022] Conveniently, the outwardly enlarging diameter of said through bore at said second post member end forms a bell-shaped second post member end.
[0023] Typically, the bell-shaped second post member end includes an outwardly rounded edge.
[0024] In one embodiment, the cord guiding member includes a cord pulley freely rotatably mounted on a hollow bracket swiveling on said post member about said post member axis, said cord pulley being located radially away from said post member axis and within a pulley plane including said post member axis.
[0025] Conveniently, the cord guiding member includes a pulley cord guide adjacent said cord pulley for maintaining the electric cord circumferentially in contact therewith.
[0026] Typically, the cord pulley is a first cord pulley, the pulley cord guide being a second cord pulley freely rotatably mounted on said hollow bracket adjacent said first cord pulley for operatively receiving the electric cord therebetween such that each said cord pulley being said pulley cord guide for the other said cord pulley, said first and second cord pulleys being within said pulley plane.
[0027] In one embodiment, the housing member includes a main housing containing said self-retracting spool member therein and attaching to a mounting bracket, said mounting bracket mounting on a stand holder for attachment to a displaceable electric machine.
[0028] Conveniently, the mounting bracket is pivotally mounted on the stand holder about an axis generally parallel to a spool axis of said self-retracting spool member for angular adjustment relative thereto so as to allow said post member axis to remain in a generally vertical orientation when said stand holder is attached to the displaceable electric machine.
[0029] Typically, the stand holder is adjustable in length for adjusting to actual dimensions of the displaceable electric machine.
[0030] Conveniently, the self-retracting spool member includes a spool freely rotatable on a fixed spool shaft with a torsion spring therebetween, whereby said torsion spring always maintaining a tension into an electric cord wound therearound.
[0031] Conveniently, the self-retracting spool member includes a selectively operable ratcheting mechanism mounted between said main housing and said spool, and connecting thereto, to selectively restrain rotation of said spool into one direction allowing unwinding of an electric cord wound therearound, said ratcheting mechanism selectively preventing operation of said torsion spring.
[0032] Typically, the main housing is a waterproof housing.
[0033] In one embodiment, the cord holder member includes a cord clamp member for clamping on an electric cord, and a securing member for releasable securing of said cord holder member to a structure, said cord clamp member connecting to the securing member via the cord state holder member.
[0034] Conveniently, the cord state holder member includes a helical tension spring having opposite ends connecting to said cord clamp member and said securing member.
[0035] Conveniently, the cord state holder member includes a tension limiter having opposite ends connecting to said cord clamp member and said securing member, said tension limiter being mounted in parallel to said helical tension spring.
[0036] Typically, the cord state holder member includes a generally flexible spring cover housing said helical tension spring therein.
[0037] Conveniently, the securing member includes a fastener for releasable fastening to a structure. Typically, the fastener is a hook or a suction cup.
[0038] According to another aspect of the present invention, there is provided a 360-degree freedom electric cord system for using with a push/pull-type electric machine displaceable by a user on a surface, said system comprising:
a housing member mountable on a displaceable electric machine and having a self-retracting spool member housing a first end portion of an electric cord connectable to the electric machine; an elongated post member defining a post member axis and first and second post member ends longitudinally opposed from one another, said first post member end connecting to the housing member, said post member having a through bore extending therealong between said first and second post member ends receiving a central portion of the electric cord therein, said second post member end having a cord guiding member allowing the electric cord to extend substantially radially therefrom and to freely rotate within a 360-degree span angle about the post member axis; and a cord holder member connectable to a structure supporting a second end portion of the electric cord adjacent thereto and away from said post member, said cord holder member including a cord state holder mechanism connecting to the electric cord to prevent torsion twisting thereof.
[0042] According to a further aspect of the present invention, there is provided a push/pull-type electric machine displaceable by a user on a surface, said electric machine comprising a 360-degree freedom electric cord device, said device including:
a housing member mountable on a displaceable electric machine and having a self-retracting spool member housing a first end portion of an electric cord to power the electric machine; an elongated post member defining a post member axis and first and second post member ends longitudinally opposed from one another, said first post member end connecting to the housing member, said post member having a through bore extending therealong between said first and second post member ends receiving a central portion of the electric cord therein, said second post member end having a cord guiding member allowing the electric cord to extend substantially radially therefrom and to freely rotate within a 360-degree span angle about the post member axis; and a cord holder member connectable to a structure supporting a second end portion of the electric cord adjacent thereto and away from said post member, said cord holder member including a cord state holder mechanism connecting to the electric cord to prevent torsion twisting thereof.
[0046] Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, in which similar references used in different Figures denote similar components, wherein:
[0048] FIG. 1 is an elevation illustration of the use of a 360-degree freedom electric cord device in accordance with an embodiment of the present invention, mounted on a push/pull-type electric machine displaceable by a user on a surface;
[0049] FIG. 2 is a partially broken exploded perspective view of the embodiment of FIG. 1 , showing the device mounting bracket adapted on an adjustable stand holder attaching to the electric machine, the holder being alternatively mountable on an optional mounting base;
[0050] FIG. 3 is a partially broken enlarged view taken along line 3 of FIG. 1 ;
[0051] FIG. 3 a is a partially broken enlarged view taken along line 3 a - 3 a of FIG. 3 ;
[0052] FIG. 4 is a partially broken enlarged view taken along line 4 of FIG. 1 , showing alternate structure anchors;
[0053] FIG. 5 is a perspective view of the embodiment of FIG. 1 , with components removed for attachment to a ceiling structure or the like;
[0054] FIG. 6 is a partially broken and partially sectioned exploded elevation view of a second embodiment of a 360-degree freedom electric cord device in accordance with the present invention;
[0055] FIG. 7 is a partially broken view taken along line 7 - 7 of FIG. 6 ;
[0056] FIG. 8 is a partially broken elevation view of the embodiment of FIG. 6 mounted inside a push/pull-type electric machine;
[0057] FIG. 9 is an elevation view of the embodiment of FIG. 6 , with components removed for laying on a surface using a mounting base; and
[0058] FIG. 10 is a partially broken enlarged perspective view taken along line 10 of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] With reference to the annexed drawings, the preferred embodiments of the present invention will be herein described for indicative purpose and by no means as of limitation.
[0060] Referring now to FIGS. 1 through 5 , there is schematically shown an embodiment of 360-degree freedom electric cord device, shown generally as 20 , for receiving an electric power cord or cable 10 , preferably provided therewith to form a 360-degree freedom electric cord system, and for using with a push/pull-type electric machine 12 displaceable by a user 14 on a surface 16 , which could be the floor, the ground or the like. The push/pull-type electric machine 12 refers to any electric machine intended to be pushed or pulled by a user 14 on a corresponding surface 16 , such as, but not limited to, a lawnmower, floor cleaner, carpet cleaner, vacuum cleaner, garden or yarn machine, snow blower, floor working or floor finishing machine, scrubber or the like.
[0061] As shown in FIG. 1 , the device 20 allows the user 14 to freely displace the electric machine 12 on the surface 16 without having to worry about the power cord 10 by ensuring that the cord 10 always remains in tension, with automatic continuous extension and retraction (as shown by arrow T), at a height generally above any obstacle (not shown), which could be chairs, tables, small trees, plants, fences, racks for goods, or the like, and preferably including the user 14 him/herself, located on the surface 16 , in a substantially horizontal orientation between the electric machine 12 and a fixed structure 18 nearby, and does not twist on itself while randomly displacing the machine 12 during operation.
[0062] The main component 22 of the device 20 is the housing member that includes a main housing 24 , typically made out of two or three parts, that houses a self-retracting spool member 26 receiving a first proximal end portion of the power cord 10 wound there around. As in typical self-retracting spools, the self-retracting spool member 26 includes a spool 28 freely rotatably mounted on a fixed shaft 30 defining a spool axis 31 and fixedly secured to the main housing 24 (see FIG. 6 ), and is connected thereto via a spiral rewind torsion spring (not shown) used to bias the spool 28 to rotate in a direction to rewind the power cord 10 there around. The size of the spiral spring may vary depending on the type and weight of the electric machine 12 , as well as with the gauge of the power cord 10 , such that the entire device 20 , along with the weight of the machine 12 function as a whole, and the device 20 , and especially the self-retracting spool 28 , does not function and remains stationary when the machine 12 is on hold, not in movement. The proximal end of the power cord 10 is typically connected to a conventional receptacle of a proximal machine power cord 32 connectable to the power cord 34 of the electric machine 12 , via a conventional reel electrical power interface (not shown) which could include an electrical switch (not shown) for selectively close or open the electrical connection there through.
[0063] During normal operation of the electric machine 12 with the present device 20 , the self-retracting spool member 26 is in a normally open configuration in which the spiral spring continuously biases the spool 28 to rewind the power cord 10 .
[0064] Typically, the self-retracting spool member 26 includes a mechanical restraint component system such as a ratchet mechanism 36 selectively activatable, and deactivatable, by the user 14 . The ratchet mechanism 36 typically includes a conventional spring loaded latch pawl (not shown) mounted on the main housing 24 via an axially biased pawl shaft (not shown) and meshable (engageable) with a corresponding conventional ratchet toothed wheel or ring (not shown) mounted on the on the spool 28 . Via a configuration knob 38 extending from the pawl shaft, the user can selectively unlatch the pawl for spring biased engagement with the ratchet wheel to have the self-retracting spool member 26 in a closed configuration, identified by corresponding first mark 38 c on the main housing 24 , in which the ratchet mechanism 36 is in operation to allow rotation of the spool 28 in a direction to unwind the power cord 10 therefrom while selectively preventing and allowing its rotation in the opposite direction under the biasing action of the spiral spring, depending on the stopping position of the spool (or the pawl angular position relative to the ratchet wheel). When the knob 38 is returned back into the latched position, the pawl is axially displaced and disengaged from the ratchet wheel to allow the continuous self-retracting operation of the spool member 26 in the open configuration, identified by corresponding second mark 38 o on the main housing 24 . It is noted that the closed configuration would preferably be used when installing the device 20 , especially the cord holder member 62 described hereinafter.
[0065] The main housing 24 typically includes a hollow branch 40 extending therefrom with a cord access opening 41 being generally tangentially oriented relative to the spool 28 to allow the power cord 10 to tangentially unwind therefrom in a generally upward direction into an elongated post member 42 mounted onto the main housing 24 . The elongated post member 42 generally defines a post member axis 44 and first proximal 46 and second distal 48 post member ends longitudinally opposed from one another. The proximal post member end 46 is typically mounted on and inserted into the main housing branch 40 up until it abuts or sits on an inner bulge 40 ′ or the like, preferably annular, and is secured thereto via a fastener such as screw 47 or the like. The post member 42 has a through bore 50 extending therealong between the post member ends 46 , 48 to receive a central portion of the power cord 10 therein. The post member 42 is typically adjustable in length, such as a telescopic rod, to allow an adjustment of the height of the power cable 10 extending between the fixed structure 18 and the electric machine 12 , especially in the region nearby the machine 12 , as shown by arrow A. Furthermore, the post member 42 is preferably slightly flexible, due to its inherent elongated structure and materials used for its components, to allow small deflections of the distal end 48 in a direction perpendicular to its axis 44 to prevent damages thereto and smooth functioning of the device 20 , as shown by arrow B.
[0066] As shown more specifically in FIGS. 1 , 3 and 3 a , the distal post member end 48 includes a cord guiding member 52 , typically secured thereto via a fastener such as screw 49 or the like, to guide the electric cord 10 in a substantially radial direction relative to the post member axis 44 , which could substantially vary from the horizontal direction as shown by arrow C and the stippled lines, and to freely rotate within a 360-degree span angle about the post member axis 44 , such that the electric cord can freely extend from the post member 42 toward a cord holder member 62 (see below) that is located in any direction over the 360-degree span relative thereto, as represented by arrows D. The cord guiding member 52 , best suited to guide small to medium gauge (low duty—mostly residential grade) power cords, typically includes a first lower cord pulley 54 freely rotatably mounted on a hollow bracket 56 that swivels on the distal post member end 48 about the post member axis 44 via a hollow bearing 58 or the like. The lower cord pulley 54 is located radially away from the post member axis 44 and within a pulley plane that includes the post member axis 44 . A pulley cord guide 60 , here in the form of a second upper cord pulley, adjacent the lower cord pulley 54 maintains the power cord 10 circumferentially in contact therewith. The upper cord pulley 60 , also freely rotatably mounted on the hollow bracket 56 and in the same pulley plane, and the lower pulley 54 operatively receive the electric cord therebetween, such that each cord pulley 54 , 60 is essentially the pulley cord guide for the other cord pulley 60 , 54 .
[0067] As shown more specifically in FIGS. 1 and 4 , the 360-degree freedom electric cord device 20 typically includes a cord holder member 62 , also referred to as the electric cord holder multi system since it performs multiple functions, that connects to the fixed structure 18 and that supports a distal second end portion of the power cord 10 adjacent the fixed structure 18 nearby (typically with a distance of 10 feet (3 meters) or less) an electrical power source, such as a conventional convenience wall power outlet 64 , and away from the post member 42 . The cord holder member 62 is typically located at a selected height sufficient to ensure the substantially horizontal orientation of the cord 10 between the cord holder member 62 and the cord guiding member 52 during operation of the device 20 , and substantially ensures a continuous holding of a natural untwisted torsion twisting of the power cord 10 there between. The cord holder member 62 includes a cord state holder mechanism 66 connecting between a cord clamp member 68 to clamp the power cord, and a securing member 70 to secure the cord holder member 62 to the fixed structure 18 .
[0068] The cord state holder member 66 , which maintains natural twist orientation (and substantially prevents torsion twisting) of power cord 10 between the cord guiding member 52 and the cord holder member 62 to keep the cord 10 in a natural position/orientation while also helping in maintaining tension therein (two physical states of the power cord 10 essential to ensure a proper operation of the self-retracting spool member 26 , along with the allowed small deflection B of the post member 42 ), typically includes a helical tension spring 72 having opposite ends, typically fixedly, connecting to the cord clamp member 68 and the securing member 70 , using bolt fasteners 73 or the like, to prevent free (unrestricted) twisting of the spring 72 relative thereto. The cord holder member 62 , and more specifically the cord state holder member 66 allow, in operation, a continuous forward and rearward shaking of the cord 10 (and consequently of the post member 42 ) to ensure the proper functioning of the self-retracting spool member 26 , especially the natural rewinding of the cord 10 on the spool 28 .
[0069] Additionally, the cord holder member 62 prevents accidental unplugging of the power cord 10 from wall power outlet 64 . In order to prevent damages to the helical tension spring 72 , the cord state holder member 66 includes a tension limiter 74 , preferably in the form of a small metallic cable or the like, of a pre-determined length slightly longer than the helical spring 72 when in the released state (to ensure a limited extension thereof), that has its opposite ends connecting also to both the cord clamp member 68 and the securing member 70 , preferably via bolt fasteners 73 , in parallel to the helical tension spring 72 . To protect the helical spring 72 from environmental conditions as well as the prevent injuries with the helical spring 72 , the cord state holder member 66 further includes a flexible (or stretchable) spring cover 76 (shown in stippled lines in FIG. 4 ) generally housing the helical tension spring 72 therein.
[0070] The cord clamp member 68 is typically in the form of two half-tubular sleeves 78 attachable to one another, via bolt fastener 79 or the like, with the power cord 10 secured in-between and typically curved (of about 90 degrees in the present case, but could be any angle, even zero degree) to properly maintain the power cord 10 in both the substantially horizontal orientation towards the post member 42 and the substantially vertical orientation towards the wall power outlet 64 adjacent the surface 16 and the fixed structure 18 .
[0071] The securing member 70 includes a structure fastener 80 to releasably attach the cord holder member 62 to the fixed structure 18 . The fastener 80 could be in the form of a closable hook directly fastening to the fixed structure 18 , as a hand rail or the like, as shown in FIG. 1 . Also, the fastener could include an anchor 82 in the form of either a hookable suction cup 82 a securable to a fixed planar surface structure as a window or the like, or a wall anchor 82 b fixed to the structure 18 , as shown in FIG. 4 , although other securing fasteners 80 are possible.
[0072] Now referring more specifically to FIGS. 1 and 2 , the housing member 22 further includes a mounting bracket 84 , of a generally U-shape, attached to the main housing 24 via fasteners 86 fastening to the fixed shaft 30 between the two sides of the U-shape, and typically mounting on a stand holder 88 via fasteners 90 , such as screws or the like engaging corresponding holder through holes 92 and bracket blind holes 94 , the stand holder 88 being attachable to a push/pull-type electric machine 12 .
[0073] The mounting bracket 84 is preferably pivotally mounted on preferably two respective side plates 89 of the stand holder 88 positioned in superposition onto the corresponding two sides of the U-shape, about an axis generally parallel to a spool axis 31 for angular adjustment relative thereto so as to allow the post member axis 44 to remain in a generally vertical orientation when the stand holder 88 is attached on the an angled component 13 of the electric machine 12 , such as the handles of a lawnmower, as in FIG. 1 . The angular adjustment, as shown by arrow R, is made possible via a bolt 96 securing to a corresponding bolt hole 98 of one of the two sides of the U-shape and being selectively positionable within a corresponding arcuate slot hole 100 of the stand holder 88 .
[0074] In order to adapt the stand holder 88 for mounting to different component sizes (widths) of different electric machines 12 , the stand holder 88 is preferably adjustable in length, as shown with the screwing knob 102 to block the sliding of an inner rectangular bar 104 inside a rectangular outer bar 106 . Typical two-part clamps 108 , 110 are provided to attach to respective bars 104 , 106 are adapted to be secured to tubular sections of the handles 13 , or the like component, of the electric machine 12 .
[0075] Alternatively, as illustrated in FIG. 5 , the embodiment 20 of the 360-degree freedom electric cord device could be detached from the electric machine 12 and suspended from a wall (not shown) or up-side-down from a ceiling using a adaptor fixture 112 connecting to the base of the U-shape of the mounting bracket 84 , or simply standing on the floor using an optional mounting base 114 (see FIG. 2 ) attachable to the stand holder 88 or the like. In such a configuration, the proximal machine power cord 32 connects to a conventional wall outlet (not shown) using a male-male plug adaptor cord 116 , and the distal end of the power cord 10 connects female-female plug adaptor cord 118 to enable any electric hand tool (not shown) or the like to be connected thereto, and therefore use the device 20 as a standard electric retractable extension cord reel, with the ratchet mechanism 36 (which may be of a different design than the one of the embodiment 20 of FIG. 2 ) in operation and the spool member 26 in a closed configuration 36 c. These plug adaptor cords 116 , 118 , and more specifically the female-female plug adaptor cord 118 , may include internal protective circuit breaker (not shown) well known in the art. The device 20 could also be similarly used as an extension reel even while remaining attached to the electric machine 12 (but electrically disconnected from the power cord 34 thereof), itself positioned adjacent a conventional wall outlet.
[0076] Referring now more specifically to FIGS. 6 through 10 , there is schematically shown a second embodiment of 360-degree freedom electric cord device, shown generally as 120 , for receiving an electric power cord or cable 10 , and substantially allowing the same freedom represented by arrows A, B, C, D, and T. In this embodiment 120 , a lower section 124 a of the main housing 124 of the housing member 122 is typically directly mounted onto the stand holder 188 , and an upper section 124 b of the main housing 124 is typically pivotally mounted on the lower section 124 a to pivot (as shown by arrow R in FIG. 7 ) about the axis of coaxial bolts 196 extending through corresponding bores of the lower section 124 a and of the upper section 124 a, as shown in FIGS. 6 and 7 .
[0077] In the case the tubular sections of the handles 13 , or the like component, of the electric machine 12 are closer from one another, the stand holder 188 could be used with additional two-part clamps 108 a, 110 a connectable under the respective free ends of the two rectangular bars 140 , 106 of the stand holder 188 .
[0078] The hollow cord access branch 140 , with cord access opening 41 , of the main housing 124 is connected thereto using bolt fasteners 141 , and typically includes a pair of parallel rollers 143 freely rotatably mounted thereon and sufficiently spaced form one another to allow the unrestricted passage of the power cord 10 there between. The proximal post member end 146 of the post member 142 includes slot channels 147 extending axially partially there along to clear the rollers 143 when inserted into the cord access opening 41 .
[0079] The distal post member end 148 , best suited to guide medium to large gauge (low and heavy duty—mostly commercial and/or industrial grade) power cords 10 , includes a cord guiding member 152 being an outwardly enlarging diameter of the through bore 150 that extends away from the first proximal post member end 146 . Typically, the outwardly enlarging diameter 152 forms a bell-shaped (as the bell of a trumpet or trombone, or tubate or concave conical shape (one-sheeted hyperboloid shape)) second post member end 148 , and the bell-shape typically includes an outwardly rounded edge 153 to ensure a smooth radial frictional sliding and unrestricted tangential rolling of the power cord 10 thereon as to be continuously oriented towards the cord holder member 62 , as well as to allow a frictionless generally axial sliding of the cord along the internal wall of the bell-shaped end 148 , without altering and/or damaging and/or even causing any wear to the power cord.
[0080] In order to prevent the distal end portion of the power cord 10 from inadvertently entering into the through bore 150 of the post member 142 when detached from the cord holder member 62 , a removable ball-shaped stopper 111 is secured on the power cord 10 .
[0081] Although not specifically described, the embodiments 20 , 120 can be used either indoor or outdoor depending of the waterproofness or water sealing of the different components thereof, and especially the main housing 24 , 124 , or the spool member 26 , having the electrical components therein, as the conventional reel electrical power interface (not shown) and the like, as well as the mechanical movable parts, as the self-retracting spool member 26 , the ratchet mechanism 36 and the like.
[0082] Even though the embodiments 20 , 120 are shown as being retrofitted onto existing on the different push/pull-type electric machines 12 , they could be permanently installed therein by the machine manufacturer or the like without departing from the scope of the present invention, as represented in FIG. 8 with the main housing 124 ′ being inside a hatched section representing a portion of a section of the body of the machine 12 .
[0083] FIG. 9 represents the embodiment 120 being used as a standard electric retractable extension cord reel, preferably with the ratchet mechanism 36 in operation and the spool member 26 in a closed configuration 36 c, detached form the electric machine 12 , and in which the post member 142 has been removed from the cord access branch 140 of the main housing 124 , and the removable ball-shaped stopper 111 from the power cord 10 , the latter not being required in this configuration since the pair of rollers 143 prevent either a narrower permanent stopper 113 or even the plug of the distal end of the power cord 10 from getting into the spool 28 (as shown in FIG. 10 ). In order to prevent the power cord 10 from getting worn out when sliding in and out, and around the cord access branch 140 , a hollow extension adaptor outlet 146 ′ is typically inserted into the cord access branch 140 with notches 143 ′ clearing rollers 143 to allow the power cord 10 to freely roll on partially exposed balls 146 a located all along the periphery of the free opening thereof. As for the other embodiment 20 , a female-female plug adaptor cord 118 , or the like is required to allow the electrical connection of a typical hand tool (not shown), and a male-male plug adaptor cord 116 , or the like is also required to allow the electrical connection of the proximal machine power cord 32 to a conventional wall outlet 64 (see FIG. 1 ). In this configuration, the stand holder 188 is typically mounted on the optional mounting base 114 , and further includes a protective side cover 115 securable to a structure wall (not shown).
[0084] Although not specifically illustrated herein, the different components, such as the housing members 24 , 124 , post members 42 , 142 and cord guide members 52 , 152 of the two embodiments 20 , 120 could be interchanged without departing from the scope of the present invention, as partially schematically represented in FIGS. 2 and 6 .
[0085] Although the present 360-degree freedom electric cord device and system has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed. | A 360-degree freedom electric cord device system contains and manages automatic extension and retraction of an electric cord/cable supplying power to a push/pull-type electric machine, either self-propelled or not, for intended displacement or steering on a surface by a user. The 360-degree freedom electric cord device system, partly mounted on the electric machine, allows the power cord to clear obstacles on the surface and includes a self-retracting spool to automatically extend and rewind the power cord and continuously keeps physical tension therein, in a straight line and a natural position, during the displacement in any direction of the electric machine. With a ratchet mechanism, the device can also suitably be used independently of the machine as an electric retractable extension cord reel. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 14/664,229, filed Mar. 20, 2015 and entitled “MODULAR STOCK FOR A FIREARM,” the entire disclosure of which is hereby incorporated by reference for all proper purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to firearms. In particular, but not by way of limitation, the present invention relates to systems and methods for firearm stocks.
BACKGROUND OF THE INVENTION
[0003] Rifles often can be fitted with two primary types of barrels: tapered or bull barrels (also known as target barrels or heavy barrels). The bull or target barrel typically has a non-tapered or cylindrical shape, whereas a tapered barrel (typically affixed to most firearms) is tapered toward the muzzle such that the diameter at the muzzle is less than a diameter at the receiver. The non-tapered nature of bull barrels means that they are steadier due to greater weight, less prone to vibration due to their geometry, and can absorb more thermal energy due to their greater mass of metal (and hence are less prone to warping under repeated firing), and are therefore preferred in some applications. Most firearm stocks are shaped to support either of these barrel types, but not both. This means that users who wish to switch barrel types must buy and install an entirely new stock when installing a new barrel. U.S. Pat. No. 8,056,278 to Bentley provides one solution to this problem in the form of a stock that supports a bull barrel and an insert that can be fitted into the stock to support a tapered barrel. Thus, the '278 patent enables a change in barrel types without the purchase and installation of an entirely new stock. However, this design suffers from the need to store and keep track of the insert when the stock is used with a bull barrel and hence without the insert.
[0004] One application where the switching of barrels occurs is the RUGER 10/22, a widespread .22 caliber rifle platform. The RUGER 10/22 includes a safety pin that is perpendicular to the barrel and arranged on the top front portion of the trigger guard just below the stock. When the trigger guard is inserted into the stock the safety pin must clear an opening in the bottom of the stock shaped to pass the trigger guard. However, the safety pin will impinge one or another side of this opening unless the safety pin is ‘centered’ in the trigger guard such that neither end of the safety pin extends beyond the sides of the trigger guard.
[0005] In other examples, it is known that less expensive or lighter rifles may be manufactured to looser tolerance standards, have excessive relative movement between the barrel and the stock, and/or have an undesirable amount of bending within the barrels themselves, any or all of which result in a less accurate weapon.
[0006] Moreover, it appears that manufacturers have recognized this as a problem as well, given that factory 10/22 rifles are generally provided with a barrel band. The barrel band is a ring of material that slips over the end of the stock and the barrel, and, by design, mounts the barrel to the stock—that is, locks the parts together. However, the barrel band does not pull the stock and the barrel together in a manner that is finely adjustable, and therefore does not improve the accuracy of the weapon.
[0007] There therefore remains a need for a system or method of improving accuracy in lighter rifles and/or rifles manufactured to relatively loose tolerance standards and/or other new and innovative features.
SUMMARY
[0008] Exemplary embodiments of the present invention that are shown in the drawings are summarized below. These and other embodiments are more fully described in the Detailed Description section. It is to be understood, however, that there is no intention to limit the invention to the forms described in this Summary of the Invention or in the Detailed Description. One skilled in the art can recognize that there are numerous modifications, equivalents and alternative constructions that fall within the spirit and scope of the invention as expressed in the claims.
[0009] In one example, a firearm stock is provided. In this example, the stock has a forend, a buttstock coupled to the forend, a selectable barrel support, and a tensioning mechanism. The forend has a recess formed from first and second inner sides and an inside bottom of the forend. The selectable barrel support is seated in the recess in the forend and is configured to support a barrel of a firearm. The selectable barrel support has an elongate frame with a longitudinal axis, a first concave barrel recess shaped to support a first barrel type and positioned on a first side of the elongate frame, and a second concave barrel recess shaped to support a second barrel type and positioned on a second side of the elongate frame. The barrel tensioning mechanism has a first support frame and an adjustment mechanism. The adjustment mechanism is configured to be positioned between the first support frame and the selectable barrel support. The first support frame has a first position and a second position and is configured to move between and including the first and second positions. In the first position the first support frame is substantially flush with or recessed in the first concave barrel recess. In the second position the first support frame protrudes into the first concave barrel recess.
[0010] In another example, a barrel support system for a firearm stock is provided. In this example, the barrel support system has a selectable barrel support, and a first barrel tensioning mechanism. The selectable barrel support has an elongate frame with a longitudinal axis, a first concave barrel recess shaped to support a first barrel type positioned on a first side of the elongate frame, and a second concave barrel recess shaped to support a second barrel type on a second side of the elongate frame. The first barrel tensioning mechanism has a first support frame and an adjustment mechanism. The adjustment mechanism is configured to be positioned between the first support frame and the selectable barrel support. The first support frame has a first position and a second position and is configured to move between and including the first and second positions. In the first position, the first support frame is substantially flush with or recessed in the first concave barrel recess. In the second position, the first support frame protrudes into the first concave barrel recess.
[0011] In another embodiment, a selectable barrel support kit is provided. In this example, the selectable barrel support kit has a selectable barrel support and a barrel tensioning mechanism. The selectable barrel support has an elongate frame with a longitudinal axis, a first concave barrel recess shaped to support a first barrel type positioned on a first side of the elongate frame, and a second concave barrel recess shaped to support a second barrel type on a second side of the elongate frame. The barrel tensioning mechanism has a first support frame, a second support frame, and an adjustment mechanism configured to adjust a seating position of at least one of the first support frame or the second support frame. The seating position is adjustable between a first position in which the at least one of the first support frame or the second support frame is flush with or recessed in the selectable barrel support, and a second position in which the at least one of the first support frame or the second support frame protrudes from the selectable barrel support.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various objects and advantages and a more complete understanding of the present invention are apparent and more readily appreciated by referring to the following detailed description and to the appended claims when taken in conjunction with the accompanying drawings:
[0013] FIG. 1 shows a firearm stock including a selectable barrel support implemented in a complete firearm;
[0014] FIG. 2 shows another view of the stock of FIG. 1 ;
[0015] FIG. 3 shows yet another view of the stock of FIG. 1 ;
[0016] FIG. 4 shows an exploded view of the stock of FIG. 1 ;
[0017] FIG. 5 shows the selectable barrel support of FIGS. 1-4 ;
[0018] FIG. 6 shows another view of the selectable barrel support of FIGS. 1-4 ;
[0019] FIG. 7A shows an additional view of the selectable barrel support of FIGS. 1-4 ;
[0020] FIG. 7B shows an additional view of the selectable barrel support of FIGS. 1-4 ;
[0021] FIG. 8 shows a cross section of the trigger guard region of the firearm of FIG. 1 ;
[0022] FIG. 9 shows another cross section of the trigger guard region of the firearm of FIG. 1 but without showing the action;
[0023] FIG. 10 shows yet another top view of the trigger guard region of the firearm of FIG. 1 but without showing the action;
[0024] FIG. 11 shows a cross sectional view of the trigger guard region of the firearm of FIG. 1 but without showing the receiver;
[0025] FIG. 12 shows another cross sectional view of the trigger guard region of the firearm of FIG. 1 but without showing the receiver;
[0026] FIG. 13 shows yet another cross sectional view of the trigger guard region of the firearm of FIG. 1 but without showing the receiver;
[0027] FIG. 14 shows a method of attaching a reversible barrel support to a firearm stock;
[0028] FIG. 15 shows another embodiment of a selectable barrel support;
[0029] FIG. 16 shows yet another embodiment of a selectable barrel support;
[0030] FIG. 17 shows a firearm stock including a selectable barrel support implemented in a complete firearm according to some embodiments;
[0031] FIG. 18 is a top view of the selectable barrel support in FIG. 17 ;
[0032] FIG. 19 illustrates a detail of the selectable barrel support and tension mechanism in FIG. 17 ;
[0033] FIG. 20 illustrates a detail of the selectable barrel support in FIG. 17 ;
[0034] FIG. 21 is a perspective view of the tensioning mechanism in FIG. 17 ;
[0035] FIG. 22 is a perspective view of another tensioning mechanism suitable for use with the barrel support in FIG. 17 ;
[0036] FIG. 23 is a perspective view of a tensioning kit according to some embodiments;
[0037] FIG. 23 a is a perspective view of another tensioning mechanism according to some embodiments;
[0038] FIG. 23 b is a perspective view of another tensioning mechanism according to some embodiments;
[0039] FIG. 23 c is a perspective view of another tensioning mechanism according to some embodiments;
[0040] FIG. 23 d is a perspective view of another tensioning mechanism according to some embodiments;
[0041] FIG. 23 e is a perspective view of another tensioning mechanism according to some embodiments;
[0042] FIG. 23 f is a perspective view illustrating features of another tensioning mechanism according to some embodiments;
[0043] FIG. 23 g is a perspective view illustrating features of another tensioning mechanism according to some embodiments; and
[0044] FIG. 24 is a flowchart of a method according to some embodiments.
DETAILED DESCRIPTION
[0045] This disclosure discusses a firearm stock including at least a selectable barrel support insert shaped to support at least two different barrel types or shapes, for instance either a tapered or bull barrel. In a particular embodiment, this discussion enables a bull barrel or barrel tapered toward a front of the barrel to be used in a firearm stock without requiring a change of the firearm stock.
[0046] FIGS. 1-4 illustrate different views of an embodiment of a firearm stock and selectable barrel support according to one embodiment of this disclosure. The selectable barrel support can be reversible, and therefore a selectable barrel support includes at least a reversible barrel support. FIG. 1 shows the firearm stock 100 including the selectable barrel support 120 (see FIGS. 2-4 ) implemented in a complete firearm 101 . The stock 100 can include a forend 102 and a buttstock 104 coupled to each other, or further including a grip section 106 coupled between the forend 102 and the buttstock 104 . In some embodiments, these two or three components can be modular and detachable. Modular means that a firearm user or a firearm manufacturer can combine any two modular parts to form a functional assembly. For instance, different forends 102 can be combined with different buttstocks 104 or different grip sections 106 . In this way, the stock 100 can be manufactured in polymer at far less cost than if the whole stock 100 were manufactured as a single component.
[0047] The firearm 101 having the stock 100 can further include a receiver 108 , a trigger assembly 110 , and a barrel 112 coupled to the receiver 108 . The barrel can rest on the selectable barrel support 120 .
[0048] The forend 102 can extend from behind the receiver 108 to a front end of the forend 114 . The illustrated stock 100 is shown with a receiver 108 and a trigger assembly 110 inserted in the stock 100 . The forend 102 can include a recess 116 formed from first and second inner sides 121 , 123 and an inside bottom 125 . The forend 102 can include a selectable barrel support 120 (see FIGS. 2-4 ) shaped to fit into the recess 116 in the forend 102 , and can include an elongate frame having a longitudinal axis 138 (see FIGS. 7A and 7B ) parallel to a longitudinal axis of the stock 100 . A longitudinal dimension 140 of the selectable barrel support 120 extending from proximal a front end of the forend 114 to proximal a front end of the receiver 108 of the firearm 101 along the longitudinal axis 138 can be greater than a lateral dimension 142 of the elongate frame. The selectable barrel support 120 can include a first side 122 and a second side 124 (see FIGS. 5-6 ), each side 122 , 124 shaped to fit a respective inner side 121 , 123 of the stock 100 . The shape of the first and second sides 122 , 124 and the respective inner sides 121 , 123 can be such that the selectable barrel support 120 releasably forms a snap, friction, or interference fit with the recess 116 in the forend 102 .
[0049] The selectable barrel support 120 includes a first concave barrel recess 126 and a second concave barrel recess 128 , each arranged on separate sides (e.g., opposing or adjacent sides) of the selectable barrel support 120 , and each configured to support a different type of barrel when the selectable barrel support 120 is engaged in the forend 102 of the firearm stock 100 . However, the selectable barrel support 120 can also be configured to support more than two different barrel types. In the illustrated embodiment, the first concave barrel recess 126 is shaped to support a tapered barrel, while the second concave barrel recess 128 is shaped to support a bull barrel or competition barrel. To do this, the first concave barrel recess 126 has radii at fore and aft portions shaped to support a first barrel type (e.g., a tapered barrel 112 ), and the second concave barrel support 128 has radii at fore and aft portions shaped to support a second barrel type. In particular, the firearm 101 of FIG. 1 has a tapered barrel 112 , and the first concave barrel recess 126 of the selectable barrel support 120 faces upward toward the barrel 112 and supports the barrel 112 . In this embodiment, the first concave barrel recess 126 has a greater radius at an aft portion 132 than at a fore portion 134 . The second concave barrel recess 128 is illustrated with an equal radius at fore and aft portions 134 , 132 of the first concave barrel recess 126 . However, the second concave barrel recess 128 can have a radius at the fore portion 134 that is equal to or greater than a radius at the aft portion 132 (e.g., where a bull barrel or competition barrel has a reverse taper—tapering from the muzzle toward the chamber). Said another way, the radii at the fore and aft portions of the first concave barrel recess 126 can be equal and the radii at the fore and aft portions of the second concave barrel recess 128 can be unequal.
[0050] In some embodiments, the first and second concave barrel recesses 126 , 128 can be configured to support barrel types other than bull or tapered barrels. For instance, one type of supported barrel can include a stepped or staggered barrel having two or more cylindrical sections, where no two adjoining sections have the same radius. Other barrel types may taper toward a middle of the barrel and then flare toward the opposing end, thus very roughly being referred to as an hourglass shape (e.g., an M16 barrel). Other barrel types may include a combination of steps as well as tapering. Some barrel types can use a stepped or staggered shape to approximate a tapered barrel (i.e., an average radius of the barrel along its length tapers). Whatever the barrel types, the first and second concave barrel recesses 126 , 128 can be configured and shaped to support any one or more barrel types (e.g., bull, tapered, staggered, hourglass, etc.), such that rotating the selectable barrel support 120 allows two or more different barrel types to be installed on the firearm 101 without a change in the stock 100 .
[0051] The selectable barrel support 120 has been shown and described as having two concave barrel recesses 126 , 128 . Yet, in other embodiments, three or more concave barrel recesses can be implemented. For instance, a selectable barrel support (or a rotatable barrel support) having three sides, and one concave barrel recess in each of those three sides, can be implemented (see, for example, FIG. 15 ). In such an embodiment, the forend 102 can include a recess 116 shaped like a “V”, having angled ribs to support two of the three sides of the selectable barrel support, or any other structure shaped to support and/or engage with the three-sided selectable barrel support. In another embodiment, the concave barrel recess can include four sides, each having a concave barrel recess configured to support a different barrel type (see, for example, FIG. 16 ).
[0052] FIG. 15 shows yet another embodiment of a selectable barrel support. The selectable barrel support 1500 includes three sides 1502 , 1504 , 1506 each arranged on separate (or adjacent) sides of the selectable barrel support 1500 , and each configured to support a different type of barrel when the selectable barrel support 1500 is engaged in the forend of a firearm stock. At least the first concave barrel recess 1508 is illustrated as shaped to support a tapered barrel, and the figure is shown from an aft perspective such that a muzzle of a barrel supported by the tapered barrel support 1500 would be directed into the page.
[0053] FIG. 16 shows yet another embodiment of a selectable barrel support. The selectable barrel support 1600 includes four sides 1602 , 1604 , 1606 , 1608 each arranged on separate sides of the selectable barrel support 1600 , and each configured to support a different type of barrel when the selectable barrel support 1600 is engaged in the forend of a firearm stock. At least the first concave barrel recess 1610 is illustrated as shaped to support a tapered barrel, and the figure is shown from a fore perspective such that a muzzle of a barrel supported by the tapered barrel support 1600 would be directed out the page. One of the four concave barrel recesses 1610 , 1612 , 1614 , 1616 , and it's corresponding side 1602 , 1604 , 1606 , 1608 would typically be arranged facing upward toward a barrel of a firearm, while an opposing side 1602 , 1604 , 1606 , 1608 would face downward into the forend of the firearm. As illustrated, the fourth side 1608 and the fourth concave barrel recess 1616 face upwards towards where a barrel might reside, while the opposing side, the second side 1604 , as well as its corresponding second concave barrel recess 1612 , face downward. The second and fourth concave barrel recesses 1612 , 1616 are shaped to support a bull barrel, while the first concave barrel recess 1610 is shaped to support a tapered barrel.
[0054] Returning to FIG. 1 , the selectable barrel support 120 is inserted in the stock 100 such that the first concave barrel recess 126 is oriented upward to support a barrel 112 (e.g., a tapered barrel) while the second concave barrel recess 128 is oriented downward toward a bottom of the recess 116 of the forend 102 . In this arrangement, the barrel 112 can rest in the first concave barrel recess 126 and contact the selectable barrel support 120 . Similarly, when the second concave barrel recess is oriented upward toward the barrel 112 , the barrel 112 can rest in the second concave barrel recess 128 and contact the selectable barrel support 120 . However, the selectable barrel support 120 can also be used with free-float barrels or assemblies and in these cases, while a free-float barrel may fit partially into the first and/or second barrel recesses 126 , 128 , the barrel does not contact the selectable barrel support 120 . In the illustrated embodiments, the first and second concave barrel recess 126 , 128 have a longitudinal dimension 144 that is less than the longitudinal dimension 140 of the selectable barrel support 120 .
[0055] To enable the selectable barrel support 120 to be releasably held in the forend 102 to the firearm stock 100 , the selectable barrel support 120 can be shaped so as to have a snap fit, friction fit, or interference fit with the recess 116 (e.g., a snap, friction, or interference fit with one or more of the first inner side 121 , the second inner side 123 , and the inside bottom 125 ). Alternatively, and as illustrated, the selectable barrel support 120 can include one or more optional fastener apertures enabling optional fasteners 136 to be used to secure the selectable barrel support 120 to the stock 100 or to the forend 102 (these are not required as the barrel 112 can also perform the role of holding the selectable barrel support 120 to the stock 100 ). The illustrated embodiment includes three optional fasteners 136 with corresponding apertures in the forend 102 , but this number is not limiting, and greater than or less than three can be implemented. In some cases, no fasteners are implemented. For instance, the selectable barrel support 120 may be releasably held in place via a snap, friction, or interference fit with the first and second inner sides 121 , 123 . The releasable hold on the selectable barrel support 120 can be aided by contact with a bottom of the barrel 112 . In other instances, limited or no friction between the barrel support 120 and the forend 102 exists, and instead, contact from a bottom of the barrel 112 holds the barrel support 120 in place. Further, in some instances, a combination of fasteners, and a snap, friction, or interference fit can be implemented. While the illustrated optional fasteners 136 are round-head screws, other types of fasteners can also be used without departing from the scope and spirit of the disclosure.
[0056] In some embodiments, the firearm stock 100 can also include structure to assist a firearms user to insert the trigger assembly 110 into the stock 100 (see FIGS. 8-13 ). A typical safety pin 170 of the trigger assembly 110 has two stable manufacturer-intended positions: fire or safe. In both of these positions, the safety pin 170 extends laterally from the trigger assembly 110 perpendicularly to the longitudinal axis of the stock 100 . For instance, in FIGS. 8, 11, and 13 the safety pin 170 extends to a left of the trigger assembly 110 , which can either be a safe or fire position, depending on specifications of the firearm 101 . In order to insert the trigger assembly 110 into the stock 100 or remove the trigger assembly 110 from the stock 100 , the trigger assembly 110 must pass at least partially through an aperture 143 (e.g., having a substantially rectangular shape). In the safe or fire positions, the safety pin 170 typically extends beyond a perimeter of the aperture 143 (see FIG. 11 ), and thus the trigger assembly 110 cannot pass at least partially through the aperture 143 while the safety pin 170 is in either the safe or fire positions (e.g., either extending to the left or right of the trigger assembly 110 ). Therefore, a user typically ‘centers’ the safety pin 170 between the safe and fire positions, which is an unstable arrangement not intended by manufacturers and one not easily achieved or maintained while the trigger assembly 110 is being passed through the aperture 143 .
[0057] To overcome this challenge, the herein disclosed stock 100 can include angled faces 146 that are adjacent to the first and second inner sides 121 , 123 and the inside bottom 125 of the stock 100 . These angled faces 146 are shaped to urge the safety pin 170 to the ‘centered’ position (i.e., centered across the trigger assembly 110 , see for instance, FIG. 12 ) when the trigger assembly 110 is inserted into the stock 100 and passed at least partially through the rectangular aperture 143 . Once the safety pin 170 has passed through the aperture 143 , the safety pin 170 can return to the safe or fire position under the force of its own internal structure (i.e., since the ‘centered’ position of FIG. 12 is unstable), as shown in FIG. 13 .
[0058] The stock 100 is illustrated as being configured for a RUGER 10/22 platform, other firearms platforms, including other .22 caliber firearms and firearms of different calibers, can also use the herein disclosed features.
[0059] FIG. 14 illustrates a method of attaching a selectable (or reversible) barrel support to a firearm stock. The method 1400 includes removing a reversible barrel support from a recess in a forend of a firearm stock, wherein the reversible barrel support has a first concave barrel recess facing upward (Block 1402 ). For the purposes of this disclosure, upward can reference a vector starting at a bottom of a forend and traversing toward a barrel of the firearm. In an embodiment, this reversible barrel support can be shaped to fit two different barrel types, for instance a bull or competition barrel, and a tapered barrel tapering from the chamber toward the muzzle. The first concave barrel recess can be shaped to support a first barrel type, and a second concave barrel recess can be shaped to support a second barrel type. Where either or both barrel types are floating, the term “support” may not include physical contact between the reversible barrel support and the one or more floating barrels. The reversible barrel support may be releasably held in place via a snap, friction, or interference fit with first and second inner sides of the forend. This releasable hold on the reversible barrel support can be aided by contact with a bottom of the barrel. In other instances, limited or no friction between the barrel support and the forend exists, and instead, contact from a bottom of the barrel holds the barrel support in place. The method 1400 further includes flipping the reversible barrel support over such that a second concave barrel recess of the reversible barrel support faces upward (Block 1404 ), and inserting the reversible barrel support back into the recess in the forend (Block 1406 ). The method 1400 can be reversed and can be repeated as many times as desired. Further, the method 1400 can be implemented when switching between any two different types of barrels.
[0060] Turning now to FIGS. 17-21 , some embodiments of the selectable barrel support 720 and/or a tensioning mechanism 750 are now described in further detail, with a general explanation of the embodiments in FIGS. 17-21 preceding the detailed explanation.
[0061] First, put broadly, the tensioning mechanism 750 may be provided so as to introduce a tensioning or expanding force between the barrel 112 and the insert 720 (and, ultimately, the forend 702 ). This is in contrast to the barrel band previously mentioned in the background of this document, which compresses the barrel and the forend together. In doing so, Applicants have introduced to users the ability to finely tune a relatively inexpensive or lighter rifle in a manner that competes with more expensive and finely toleranced rifles.
[0062] In some embodiments, a tensioning mechanism 750 may be provided so as to enable a user to adjust a relationship between the barrel 112 and the selectable barrel support 720 . For example, tolerance stack-up across multiple components and/or manufacturing inconsistencies in the barrel 112 and/or the selectable barrel support 720 or forend 702 may result in the selectable barrel support 120 (illustrated and described with reference to FIGS. 1-16 ) not fully contacting the barrel 112 and/or a loose relationship between the barrel 112 and the selectable barrel support 120 . To overcome this potential problem, the user may adjust the tensioning mechanism 750 , seated in the selectable barrel support 720 , as illustrated in FIGS. 17 and 19 .
[0063] In some embodiments, the selectable barrel support 720 is shaped to distribute a concentrated force from the tensioning mechanism 750 (caused by the barrel 112 ) across a broader surface area on the forend 702 , while simultaneously roughly limiting motion between the barrel 112 and the selectable barrel support 720 , providing a strengthening and/or stiffening effect to the barrel 112 or forend 702 , and/or providing an additional barrier (such as supplemental to the forend 702 ) between a user and the barrel 112 .
[0064] When referencing features illustrated in FIGS. 17-21 , unless otherwise described, the features are substantially as illustrated and described with reference to FIGS. 1-16 .
[0065] As previously described with reference to FIGS. 1-16 , the selectable barrel support 720 may be provided with a first concave recess 726 and a second concave recess 728 , (or third and fourth recesses, not illustrated), first and second sides 722 , 724 , and fastener(s) 736 . These features are substantially as described with reference to first and second sides 122 , 124 , first and second concave recesses 126 , 128 , and fasteners 136 , except as otherwise described below.
[0066] Similarly, the selectable barrel support 720 is configured for attachment to a firearm stock 700 having a forend 702 that is coupled to a buttstock 104 with a grip 106 substantially as previously described and illustrated, unless otherwise described below.
[0067] Some embodiments provide a firearm stock 700 , a buttstock 104 coupled to the forend 702 , a selectable barrel support 720 , and a barrel tensioning mechanism 750 . The firearm stock 700 may have a forend 702 comprising a recess formed from first and second inner sides 721 , 723 and an inside bottom of the forend 702 .
[0068] The selectable barrel support 720 may be removably seated in the recess in the forend 702 , and is configured to support a barrel 112 of a completed firearm 701 . As illustrated, the selectable barrel support 720 may have an elongate frame with a longitudinal axis and a first concave barrel recess 726 shaped to support a first barrel type (see e.g. barrel 112 illustrated in FIG. 17 ). The first concave barrel recess 726 may be positioned on a first side 722 of the elongate frame. A second concave barrel recess 728 shaped to support a second barrel type (for example a bull barrel, not illustrated) may be positioned on a second side 724 of the elongate frame.
[0069] With specific reference to FIG. 21 , a barrel tensioning mechanism 750 is provided in some embodiments. The barrel tensioning mechanism 750 may have a first support frame 752 and an adjustment mechanism 754 . The adjustment mechanism 754 may be configured to be positioned between the first support frame 752 and the selectable barrel support 720 (see FIG. 17 ). By adjusting the adjustment mechanism 754 a seating position of the first support frame 752 can be moved between a first position wherein the first support frame 752 is substantially flush with the first concave barrel recess 726 or recessed in the first concave barrel recess 726 , and a second position wherein the first support frame 752 protrudes into the first concave barrel recess 726 . In some embodiments, the first support frame 752 has one or more legs 764 , 766 , which may serve to strengthen and/or align the support frame 752 relative to the selectable barrel support 720 . Where a second support frame 772 (see e.g. FIG. 23 ) is provided, leg(s) 764 , 766 of the first support frame 752 may abut or align with leg(s) 784 , 786 of the second support frame 772 (not illustrated, and not required in all embodiments). In some embodiments, the leg(s) 764 , 766 of a first support frame 752 may be unitary with or coupled to the leg(s) 784 , 786 of a second support frame 772 . In some embodiments, a first leg 764 in the first support frame 752 may abut, couple to, or be unitary with a first leg 784 in the second support frame 774 . In some embodiments, first and second support frames 752 , 772 may seat in the selectable barrel support 720 about a support surface 768 (see e.g. FIG. 20 ).
[0070] Although a threaded mechanism such as a screw is generally illustrated as the adjustment mechanism 754 , those skilled in the art will understand that a thread is only one type of cammed feature, and that other cammed mechanisms may be suitable for use as an adjustment mechanism 754 . Those skilled in the art will also recognize that other solutions for selective adjustment include, but are not limited to, detent mechanisms, interference fittings, gear mechanisms, levers, and/or other means known to those skilled in the art. A threaded mechanism nonetheless may be selected as the adjustment mechanism 754 so as to provide infinite adjustment, and, in turn, fine tuning capabilities between the barrel 112 and the barrel support 720 or forend 702 .
[0071] Although not illustrated, in some embodiments, the tensioning mechanism 750 may be configured to apply a first pressure and a second pressure on the barrel 112 . That is, in a first position, the tensioning mechanism 750 may be configured to not apply a pressure on the barrel 112 , and, in contrast, the tensioning mechanism 750 may be configured to apply a pressure on the barrel 112 when in the second position. For instance, the actual position of the barrel 112 (relative to the selectable barrel support 720 ) may not change when the tensioning mechanism 750 is moved between the first and second positions, even though the tensioning mechanism 750 may touch or apply a force to the barrel 112 in either or both positions. Instead, what changes is the amount of force the tensioning mechanism 750 applies on the barrel 112 . In other words, the pressure or tension can be used to dampen vibrations even without any noticeable physical differences in the barrel 112 . In some embodiments, the tensioning mechanism 750 may be configured to apply a first force on the barrel 112 when in the first position, and a second force on the barrel 112 when in the second position, the second force greater than the first force. In some embodiments, the tensioning mechanism 750 may be configured to cause the barrel 112 and/or the forend 702 of the stock 700 to flex slightly, relative to the selectable barrel support 720 when the tensioning mechanism 750 is in the second position.
[0072] In some embodiments, the tensioning mechanism 750 is removable from the assembly; for example, the tensioning mechanism 750 may simply be seated in the selectable barrel support 720 . In some embodiments, the tensioning mechanism 750 may be removably coupled to the selectable barrel support 720 . For example, the adjustment mechanism 754 may be threaded to, cammed, or pass through the support body 752 to couple the tensioning mechanism 750 to the selectable barrel support 720 . In some embodiments, any means of adjustably and/or removably coupling the tensioning mechanism 750 to the selectable barrel support 720 or the forend 702 are envisioned. Various means of fastening, including, without limitation, one or more of screws, levers, snap-fit mechanism, friction interfaces, or other fastening means now available or as-yet to be developed are envisioned to provide a removable coupling.
[0073] Relatedly, the first support body 752 may be removably coupled to the adjustment mechanism 754 . For example, various means of fastening, including, without limitation, one or more of screws, levers, snap-fit mechanism, friction interfaces, or other fastening means now available or as-yet to be developed are envisioned to removably couple the first support body 752 to the adjustment mechanism 754 .
[0074] Turning now to FIG. 18 , the selectable barrel support 720 may have a recess 756 configured to receive a tensioning mechanism 750 , or, put simply, the tensioning mechanism 750 may be seated in the selectable barrel support 720 at the recess 756 . As illustrated in FIG. 20 , the recess 756 may include a support surface 768 in the selectable barrel support 720 . In some embodiments, the adjustment mechanism 754 may be a threaded or cammed fastener or set screw rotatingly engaged with a socket feature 769 in the selectable barrel support 720 . Rotation of the adjustment mechanism 754 causes the adjustment mechanism 754 to move between a first position and a second position. When the adjustment mechanism 754 is in the first position and a user seats the support body 752 in the selectable barrel support 720 , the support body 752 is in a first position in which a curved support surface 758 (see FIG. 21 ) in the main body 752 is substantially flush with or recessed in the first concave barrel recess 726 . When the adjustment mechanism 754 is in the second position and a user seats the support body 752 in the selectable barrel support 720 , the support body 752 is in a second position in which the curved support surface 758 (see FIG. 21 ) in the support body 752 protrudes into the first concave barrel recess 726 . Those skilled in the art will understand that a surface 762 opposing the curved support surface 758 provides the ability to apply, using the adjustment mechanism 754 or screw, a counter force for supporting the barrel 112 .
[0075] Causing the support body 752 (see FIG. 21 ) to protrude into the first concave barrel recess 726 in this manner may, when part of a complete firearm 701 , eliminate problems of tolerance stack-up and/or manufacturing inconsistencies in the firearm 701 , such as the barrel 112 and/or the selectable barrel support 720 and/or forend 702 . For example, while the interior portions of a barrel 112 may be manufactured to a particular tolerance, the exterior of the barrel may be less controlled, resulting in potential adverse relationships between the barrel and the selectable barrel support 720 . Moreover, after market manufacturers and/or modification may further exacerbate the problems with tolerances and inconsistencies.
[0076] In some embodiments, the selectable barrel support 720 is shaped to distribute a concentrated force from the tensioning mechanism 750 (caused by the barrel 112 ) across a broader surface area on the forend 702 , while simultaneously roughly limiting motion between the barrel 112 and the selectable barrel support 720 , providing a strengthening and/or stiffening effect to the barrel 112 or forend 702 , and/or providing a barrier between a user and the barrel 112 . In some embodiments, the tensioning mechanism 750 provides a user the ability to finely tune a position of the barrel 112 relative to the forend 702 to account for tolerance stack-up and other manufacturing inconsistencies in the barrel 112 , the selectable barrel support 720 , and/or the forend 702 .
[0077] With reference now to FIG. 22 , in some embodiments, a second tensioning mechanism 770 having a second support frame 772 and optionally a second tensioning mechanism 754 may be provided. The second support frame 772 may have a curved support surface 778 configured to support a second barrel shape when protruding into a second concave barrel recess 728 of the selectable barrel support 720 (see e.g. FIG. 17 and FIG. 22 ).
[0078] In some embodiments, a firearm barrel support system 760 may be provided, as illustrated in FIGS. 17-21 . The system 760 may have a selectable barrel support 720 , a forend 702 for a stock 700 , a tensioning mechanism 750 , and one or more fasteners 736 for coupling the selectable barrel support 720 to the forend 702 . The tensioning mechanism 750 may have a first support body 752 and an adjustment mechanism 754 . In some embodiments, the tensioning mechanism 750 may include a second support body 772 , or in some embodiments, a first tensioning mechanism 750 and a second tensioning mechanism 770 may be provided. In some embodiments, the first and second support bodies 752 , 772 may be unitary with or coupled to each other.
[0079] Turning now to FIG. 23 , in some embodiments, a barrel support kit 790 may be provided. The barrel support kit 790 or tensioning mechanism 791 may include a first support frame 752 , a second support frame 772 , and an adjustment mechanism 754 . That is, the first support frame 752 may be configured to conform to, sit flush with, or recess in the first concave barrel recess 726 , and the second support frame 772 may be configured to conform to, sit flush with, or recess in the second concave barrel recess 728 . Relatedly, the adjustment mechanism 754 may be configured to adjust either the first support body 752 and/or the second support body 772 . The tensioning mechanism 791 may have a first support body 752 , a second support body 772 , and an adjustment mechanism 754 .
[0080] Although the first and second support bodies 752 , 772 and adjustment mechanism 754 are illustrated as separate components, those skilled in the art will readily envision a number of variations. For example, the first support body 752 and the second support body 772 may be unitary with each other or coupled together about the support surface 768 (see FIG. 20 ), with the adjustment mechanism 754 threaded to, cammed, or otherwise movabley coupled to the socket feature 769 . More specifically, the curved support surface 758 in the first support body 752 may be rotated 180 degrees relative to the curved support surface 778 in the second support body 772 . In some embodiments, a passage (not illustrated) may be provided through the curved support surface 758 , 778 in either or both of the support bodies 752 , 772 , to give a user access to one or more adjustment mechanisms 754 positioned between the kit 790 (or tensioning mechanism 791 , or support bodies 752 , 772 ) and the selectable barrel support 720 .
[0081] In some embodiments, an aperture (not illustrated) may be provided in the forend 702 , such as at a bottom or side of the forend 702 , to give access to the adjustment mechanism 754 and/or tensioning mechanism 750 . Specifically, the aperture may be positioned on a bottom side of the forend 702 (see FIG. 17 ), and shaped such that a user may access the adjustment mechanism 754 through the bottom of the forend 702 . In some embodiments, a user may access and manipulate the adjustment mechanism 754 through the aperture in the forend 702 using a screwdriver or other device for rotating the adjustment mechanism 754 , which may have a tool interface on the bottom side. In some embodiments, the user may repeatedly adjust the adjustment mechanism 754 , and hence the tensioning mechanism 750 , and fire the weapon 701 (see FIG. 17 ) without disassembling the forend 702 or other components from the barrel 112 .
[0082] In some embodiments, and as illustrated in FIG. 23 a , a tensioning mechanism 800 having a dual support 802 may be provided, wherein the dual support 802 has a first support body 752 with a first curved surface 758 on a first side 804 and second support body 772 with a second curved surface 778 on a second side 806 , and a screw or other adjustment mechanism 754 configured to be positioned between the dual support 802 and the selectable barrel support 720 .
[0083] Put another way, the first support body 752 and the second support body 772 may be unitary, permanently coupled to each other, or removably coupled to each other. Recesses 855 in the first and second support bodies 752 , 772 may provide a stabilizing feature and/or an abutment against which the tensioning mechanism 800 may seat. Those skilled in the art will understand that, where the adjustment mechanism 754 is a threaded screw, the adjustment mechanism 754 may be threaded to the tensioning mechanism 750 , 770 , 800 or the selectable barrel support 720 .
[0084] Turning now to FIG. 23 b , in some embodiments, a tensioning mechanism 900 otherwise substantially as described with reference to FIG. 23 a may be provided with a passage 955 a through the dual support 902 , to give a user access to the adjustment mechanism. For example, the adjustment mechanism 954 may be threaded or cammed to engage the socket feature 769 in the selectable barrel support 720 (see e.g. FIG. 20 ), and a user may adjust the adjustment mechanism 954 without unseating (or uncoupling or removing) the dual support 954 , or, where applicable, the first and/or second support bodies 752 , 772 . For example, a tool engagement 953 , such as a flathead interface, may be provided on the adjustment mechanism 954 for engagement with a tool through the dual support 902 or support body 752 , 772 . Those skilled in the art will understand that the passage and tool engagement features are applicable to other embodiments, including those illustrated in FIGS. 17-23 .
[0085] In some embodiments, the tensioning mechanism 1000 , and as illustrated in FIG. 23 c , the adjustment mechanism 1054 may be rotatingly coupled to or threaded to a dual support 1002 , which may have a first support body 752 with a first curved surface 758 to abut a first barrel, and a second support body 772 having a second curved surface 778 to abut a second barrel. The adjustment mechanism 1054 may include a tool engagement feature 1053 on a first end and a barrel support interface 1057 on a second end.
[0086] Turning now to FIG. 23 d , in some embodiments, the tensioning mechanism 1100 may have a dual support body 1101 substantially as previously described, with a first support body 752 and a second support body 772 unitary with or coupled to the first support body 752 . The first support body 752 has a first barrel interface 1102 with a first curved support surface 758 and a first flange 1106 recessed in the first curved support surface 758 . That is, the first barrel interface 1102 may be configured to abut a first barrel of a firearm and alternatively abut a ledge or support surface 768 in a selectable barrel support 720 . The second support body 772 similarly has a second barrel interface 1104 with a second curved support surface 778 and a second flange 1108 recessed in the second curved support surface 778 . That is, the second barrel interface 1104 may be configured to abut a second barrel of a firearm and alternatively abut a ledge or support surface 768 in a selectable barrel support 720 . In the embodiment illustrated in FIG. 24 d , a passage 1110 in the dual support 1101 may be provided for rotatingly engaging an adjustment mechanism 754 that abuts a flange or support surface 768 in the selectable barrel support 720 . The adjustment mechanism 754 may have a tool interface 753 such as a screwdriver interface on both ends, such that user rotation or adjustment of the adjustment mechanism 754 causes the adjustment mechanism 754 to move relative to the dual support 1101 , and, in turn, adjust a seating position of the tensioning mechanism 1100 relative to the selectable barrel support 720 . Those skilled in the art will understand that a user may first seat the tensioning mechanism 1100 with a first orientation to support a first barrel, remove the tensioning mechanism 1100 , and seat the tensioning mechanism 1100 with a second orientation to support a second barrel. In either or both orientations, the user may adjust the adjustment mechanism 754 to adjust the seating position of the tensioning mechanism 1100 by inserting a tool through the passage 1110 to rotate the adjustment mechanism 754 , or otherwise substantially as previously described herein.
[0087] Those skilled in the art can readily envision any number of variations to the tensioning mechanism 750 , 770 , 791 , 800 , 900 , 1000 , 1100 as taught herein without deviating from the scope of the invention as claimed.
[0088] To name just a few examples, those skilled in the art will understand that, although the dual support 802 , 902 , 1002 , 1101 and support bodies 752 , 772 described in the preceding paragraphs are illustrated with particular outer contouring, this feature is not necessary, and, specifically, the dual support 802 , 902 , 1002 and/or the support bodies 752 , 772 may be modified so as to seat in or slide within the selectable barrel support 720 in a stable manner. Likewise, the selectable barrel support 720 may be configured to receive and constrict motion of the dual support 802 , 902 , 1002 and/or the support bodies 752 , 772 in a stable manner.
[0089] Moreover, as illustrated in FIG. 23 e , a tensioning mechanism 1200 may have a dual support 1202 and an adjustment mechanism 1204 . The adjustment mechanism 1204 may be include any feature such as, but not limited to, a rack and pinion mechanism, a detent system, a gear mechanism, a selective interference fit, a lever mechanism, a jack screw variant, and/or a lead screw, configured to effectuate linear motion of the dual support relative to the selectable barrel support 720 .
[0090] Turning now to FIG. 23 f , it illustrates a general layout of an embodiment of a tensioning mechanism 1250 and a barrel 112 . In some embodiments, the tensioning mechanism 1250 may have a support surface 1258 and an adjustment mechanism 1254 , such that manipulation of the adjustment mechanism 1254 may cause the tensioning mechanism 1250 and/or support surface 1258 to rotate about an axis that is transverse relative to the longitudinal axis of the barrel 112 . The adjustment mechanism 1254 may include a ratcheting feature (not illustrated) to interface with the barrel support 720 or forend 702 to allow fine adjustment/rotation of the tensioning mechanism 1250 or selective positioning of the tensioning mechanism 1250 . Those skilled in the art will understand that a ratcheting feature is not the only solution; other solutions for selective positioning include, but are not limited to, detent mechanisms, interference fittings, gear mechanisms, levers, and/or other means known to those skilled in the art for controlling rotation of a mounted component.
[0091] As illustrated in FIG. 23 g , in some embodiments, the tensioning mechanism 1350 may include a lever mechanism 1352 rotatingly mounted at a mounting point 1353 to the forend 702 and/or the barrel support 720 , such that adjustment of the adjustment mechanism 1354 may cause different regions of a support surface 1358 to abut or engage the barrel 112 . As in the embodiment illustrated in FIG. 23 f , the tensioning mechanism 1350 illustrated in FIG. 23 g may have a support surface 1358 and an adjustment mechanism 1354 , such that manipulation of the adjustment mechanism 1354 may cause the tensioning mechanism 1350 and/or support surface 1358 to rotate about an axis that is transverse relative to the longitudinal axis of the barrel 112 . The adjustment mechanism 1354 may include a threaded or cammed engagement with the barrel support 720 or the forend 702 to allow fine adjustment/rotation of the tensioning mechanism 1350 or selective positioning of the tensioning mechanism 1350 . Those skilled in the art will understand that a screw or cam mechanism is not the only solution; other solutions for selective positioning include, but are not limited to, detent mechanisms, interference fittings, gear mechanisms, levers, and/or other means known to those skilled in the art for controlling rotation of a mounted component.
[0092] Turning now to FIG. 24 , in another example, a method 2400 of attaching a reversible barrel support to a firearm stock is provided. In this example, the method includes placing 2402 a reversible barrel support in a recess in a forend of a firearm stock, wherein the reversible barrel support has a first concave barrel recess facing upward. The method also includes seating 2404 a barrel tensioning mechanism in the first concave barrel recess, the barrel tensioning mechanism having a first support frame and an adjustment mechanism. Seating 2404 includes positioning 2404 a the adjustment mechanism against the reversible barrel support, and adjusting 2404 b the adjustment mechanism to control a seating position of the first support frame. Adjustment 2404 b of the adjustment mechanism moves the seating position of the first support frame between a first position in which the first support frame is flush with or recessed in the first concave barrel recess and a second position in which the first support frame protrudes into the first concave barrel recess.
[0093] In some embodiments, adjustment 2404 b is performed after assembling a firearm or a barrel of a firearm to the stock, and without disassembling the firearm or barrel from the stock. In some embodiments, adjustment 2404 b is performed by inserting a tool into an aperture in the forend. Adjustment 2404 b may be achieved using the embodiments illustrated in FIGS. 17-23G .
[0094] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. More specifically, disclosure of an act or method should be understood as a disclosure of a related device for carrying out the act or method; likewise, disclosure of a device for carrying out an act or method shall be understood as a disclosure of the act or method. For example, disclosure of a fastener shall be understood to include the act of fastening, and vice versa. Moreover, those skilled in the art can readily recognize that numerous variations and substitutions may be made in the invention, its use and its configuration to achieve substantially the same results as achieved by the embodiments described herein. Accordingly, there is no intention to limit the invention to the disclosed exemplary forms. Many variations, modifications and alternative constructions fall within the scope and spirit of the disclosed invention as expressed in the claims. | This disclosure describes systems, methods, and apparatus for a selectable barrel support that can be inserted into a forend of a firearm stock to support a first barrel type and flipped, rotated, or otherwise moved to support a second barrel type (or third or fourth barrel types). A tensioning mechanism is provided. Bull and tapered barrels are examples of two barrel types that the selectable barrel support can be used to support. The selectable barrel support enables a firearm owner or gunsmith to exchange barrel types on a firearm without having to switch out the firearm stock. | 5 |
FIELD OF THE INVENTION
The present invention relates to the refinery processing of crude oil. Specifically, it is directed toward the problem of corrosion of refinery equipment caused by corrosive elements found in the crude oil.
BACKGROUND
Hydrocarbon feedstocks such as petroleum crudes, gas oil, etc. are subjected to various processes in order to isolate and separate different fractions of the feedstock. In refinery processes, the feedstock is distilled so as to provide light hydrocarbons, gasoline, naphtha, kerosene, gas oil, etc.
The lower boiling fractions are recovered as an overhead fraction from the distillation zones. The intermediate components are recovered as side cuts from the distillation zones. The fractions are cooled, condensed, and sent to collecting equipment. No matter what type of petroleum feedstock is used as the charge, the distillation equipment is subjected to the corrosive activity of acids such as H 2 S, HCl, organic acids and H 2 CO 3 .
Corrosive attack on the metals normally used in the low temperature sections of a refinery process system, i.e. (where water is present below its dew point) is an electrochemical reaction generally in the form of acid attack on active metals in accordance with the following equations:
(1) at the anode
Fe⃡Fe.sup.++ +2(e)
(2) at the cathode
2H.sup.+ +2(e)⃡2H
2H⃡H.sub.2
The aqueous phase may be water entrained in the hydrocarbons being processed and/or water added to the process for such purposes as steam stripping. Acidity of the condensed water is due to dissolved acids in the condensate, principally HCl, organic acids and H 2 S and sometimes H 2 CO 3 . HCl, the most troublesome corrosive material, is formed by hydrolysis of calcium and magnesium chlorides originally present in the brines.
Corrosion may occur on the metal surfaces of fractionating towers such as crude towers, trays within the towers, heat exchangers, etc. The most troublesome locations for corrosion are tower top trays, overhead lines, condensers, and top pump around exchangers. It is usually within these areas that water condensation is formed or carried along with the process stream. The top temperature of the fractionating column is usually, but not always, maintained about at or above the boiling point of water. The aqueous condensate formed contains a significant concentration of the acidic components above-mentioned. This high concentration of acidic components renders the pH of the condensate highly acidic and, of course, dangerously corrosive. Accordingly, neutralizing treatments have been used to render the pH of the condensate more alkaline to thereby minimize acid-based corrosive attack at those apparatus regions with which this condensate is in contact.
One of the chief points of difficulty with respect to corrosion occurs above and in the temperature range of the initial condensation of water. The term "initial condensate" as it is used herein signifies a phase formed when the temperature of the surrounding environment reaches the dew point of water. At this point a mixture of liquid water, hydrocarbon, and vapor may be present. Such initial condensate may occur within the distilling unit itself or in subsequent condensors. The top temperature of the fractionating column is normally maintained above the dew point of water. The initial aqueous condensate formed contains a high percentage of HCl. Due to the high concentration of acids dissolved in the water, the pH of the first condensate is quite low. For this reason, the water is highly corrosive. It is important, therefore, that the first condensate be rendered less corrosive.
In the past, highly basic ammonia has been added at various points in the distillation circuit in an attempt to control the corrosiveness of condensed acidic materials. Ammonia, however, has not proven to be effective with respect to eliminating corrosion occurring at the initial condensate. It is believed that ammonia has been ineffective for this purpose because it does not condense completely enough to neutralize the acidic components of the first condensate.
At the present time, amines such as morpholine and methoxypropylamine (U.S. Pat. No. 4,062,746) are used successfully to control or inhibit corrosion that ordinarily occurs at the point of initial condensation within or after the distillation unit. The addition of these amines to the petroleum fractionating system substantially raises the pH of the initial condensate rendering the material noncorrosive or substantially less corrosive than was previously possible. The inhibitor can be added to the system either in pure form or as an aqueous solution. A sufficient amount of inhibitor is added to raise the pH of the liquid at the point of initial condensation to above 4.5 and, preferably, to at least about 5.0.
Commercially, morpholine and methoxypropylamine have proven to be successful in treating many crude distillation units. In addition, other highly basic (pKa>8 ) amines have been used, including ethylenediamine and monoethanolamine. Another commercial product that has been used in these applications is hexamethylenediamine.
A specific problem has developed in connection with the use of these highly basic amines for treating the initial condensate. This problem relates to the hydrochloride salts of these amines which tend to form deposits in distillation columns, column pumparounds, overhead lines and in overhead heat exchangers. These deposits manifest themselves after the particular amine has been used for a period of time. These deposits can cause both fouling and corrosion problems and are most problematic in units that do not use a water wash.
RELATED ART
Conventional neutralizing compounds include ammonia, morpholine and ethylenediamine. U.S. Pat. No. 4,062,764 discloses that alkoxylated amines are useful in neutralizing the initial condensate.
U.S. Pat. No. 3,472,666 suggests that alkoxy substituted aromatic amines in which the alkoxy group contains from 1 to 10 carbon atoms are effective corrosion inhibitors in petroleum refining operations. Representative examples of these materials are aniline, anisidine and phenetidines.
Alkoxylated amines, such as methoxypropylamine, are disclosed in U.S. Pat. No. 4,806,229. They may be used either alone or with the film forming amines of previously noted U.S. Pat. No. 3,472,666.
The utility of hydroxylated amines is disclosed in U.S. Pat. No. 4,430,196. Representative examples of these neutralizing amines are dimethylisopropanolamine and dimethylaminoethanol.
U.S. Pat. No. 3,981,780 suggests that a mixture of the salt of a dicarboxylic acid and cyclic amines are useful corrosion inhibitors when used in conjunction with traditional neutralizing agents, such as ammonia.
Many problems are associated with traditional treatment programs. Foremost is the inability of some neutralizing amines to condense at the dew point of water thereby resulting in a highly corrosive initial condensate. Of equal concern is the formation on metallic surfaces of hydrochloride or sulfide salts of those neutralizing amines which will condense at the water dew point. The salts appear before the dew point of water is reached and result in fouling and underdeposit corrosion, often referred to as "dry" corrosion.
Accordingly, there is a need in the art for a neutralizing agent which can effectively neutralize the acidic species at the point of the initial condensation without causing the formation of fouling salts with their corresponding "dry" corrosion.
GENERAL DESCRIPTION OF THE INVENTION
The above and other problems are addressed by the present invention. It has been discovered that certain amines may be chosen for their ability to neutralize corrosion causing acidic species at the dew point of water which will not form salt precipitates prior to reaching the dew point temperature. By selecting amines having pKa between 5 and 8 and which form salts that have a high equilibrium vapor pressure, a neutralizing treatment program achieving the above objectives has been discovered.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows vapor pressure as a function of temperature.
FIG. II shows the affect of blending low and high pKa amines on HCl neutralization.
FIG. III shows the buffering effect of low pKa amines.
DETAILED DESCRIPTION OF THE INVENTION
The proper selection of a neutralizing agent for petroleum refining operations according to the present invention requires that the agent effectively neutralize the acidic corrosion causing species at the initial condensation or dew point of the water. Additionally, the agent should not form salts with those acidic species above the water dew point which, in turn, then deposit on the metallic surfaces of the overhead equipment resulting in fouling and/or underdeposit or "dry" corrosion. The deposition of these salts is due to the presence of sufficient hydrochloric acid and amine so that the amine salt vapor pressure is exceeded at temperatures above the water dew point. The advantage of using low pKa amines in place of traditional (highly basic) amines is that they form hydrochloride salts that do not exceed their vapor pressure until after the water dew point is reached. Once the dew point is achieved, free water is present to wash away the amine hydrochloride salts that may subsequently form.
It has been discovered that by selecting less basic amines having a pKa of from 5 to 8, the above noted objectives are met. This is an unexpected departure from conventional teaching and practice in which strongly basic amines are used. It is thought by other practitioners that the stronger the base the better because the very acidic pH of the initial condensate requires the need for a strong base to raise the pH to less corrosive levels, such as to 4.0 and above.
The following is a list of characteristic amines shown with their corresponding pKa values. These amines are exemplary of the neutralizing agents contemplated by the present invention. This list is not intended to limit the scope of useful compounds to only those shown.
______________________________________Amine pKa______________________________________pyridine 5.252-amino pyridine 6.822-benzyl pyridine 5.132,5 diamino pyridine 6.482,3 dimethyl pyridine 6.572,4 dimethyl pyridine 6.993,5 dimethyl pyridine 6.15methoxypyridine 6.47isoquinoline 5.421-amino isoquinoline 7.59N,N diethylaniline 6.61N,N dimethylaniline 5.152-methylquinoline 5.834-methylquinoline 5.67ethylmorpholine 7.60methylmorpholine 7.142-picoline 5.903-picoline 5.684-picoline 6.02______________________________________
The selection of less basic amines useful as effective neutralizers is augmented by an analysis of the tendency of a selected amine to form a salt precipitate with the acidic species. Neutralizing amines having a low precipitation potential are desired and are determined by analyzing the equilibrium vapor pressures of the corresponding amine salt. Knudsen sublimation pressure testing was conducted on numerous amine chloride salts to measure their equilibrium vapor pressures at various temperatures. This testing procedure is described in detail in experimental Physical Chemistry, Farrington, et al, McGraw Hill, 1970, pp 53-55. The procedure defined therein is hereby incorporated by reference.
FIG. I shows the vapor pressures of 4-picoline HCl plotted as a function of temperature and was constructed from data collected by the Knudsen sublimation technique. These data are plotted the log of vapor pressure (in atmospheres) vs. 1/T°K in order to generate a linear plot. Such plots were drawn and linear equations determined for each material tested.
Table I shows the vapor pressures of various amine hydrochloride salts at temperature intervals of 10° F. between 200° F. and 350° F. These values are calculated from the above derived equations. It is evident that as temperature rises, the equilibrium vapor pressure of all salts tested increases. However over the broad temperature range shown in Table I, the picoline and pyridine hydrochloride salts exhibit vapor pressures which are 100 to 1,000 those of NH 4 Cl or morpholine hydrochloride.
TABLE I__________________________________________________________________________Vapor Pressure (ATM) vs Temperature ofAmine Hydrochloride SaltsF° 4-Picoline Pyridine Methylmor- MorpholineTemp NH.sub.4 Cl HCl HCl pholine HCl HCl__________________________________________________________________________200 1.0 × 10.sup.-6 1.13 × 10.sup.-4 1.88 × 10.sup.-4 3.16 × 10.sup.-6 9.5 × 10.sup.-7210 2.0 × 10.sup.-6 1.99 × 10.sup.-4 2.92 × 10.sup.-4 5.45 × 10.sup.-6 1.0 × 10.sup.-6220 3.0 × 10.sup.-6 3.45 × 10.sup.-4 4.50 × 10.sup.-4 9.26 × 10.sup.-6 2.0 × 10.sup.-6230 5.0 × 10.sup.-6 5.90 × 10.sup.-4 6.83 × 10.sup.-4 1.55 × 10.sup.-5 2.0 × 10.sup.-6240 7.0 × 10.sup.-6 9.94 × 10.sup.-4 1.03 × 10.sup.-3 2.55 × 10.sup.-5 3.0 × 10.sup.-6250 1.0 × 10.sup.-5 1.65 × 10.sup.-3 1.52 × 10.sup.-3 4.14 × 10.sup.-5 4.0 × 10.sup.-6260 2.0 × 10.sup.-5 2.70 × 10.sup.-3 2.23 × 10.sup.-3 6.64 × 10.sup.-5 6.0 × 10.sup.-6270 2.0 × 10.sup.-5 4.34 × 10.sup.-3 3.24 × 10.sup.-3 1.05 × 10.sup.-4 7.0 × 10.sup.-6280 3.0 × 10.sup.-5 6.92 × 10.sup.-3 4.66 × 10.sup.-3 1.64 × 10.sup.-4 9.0 × 10.sup.-6290 5.0 × 10.sup.-5 1.09 × 10.sup.-2 6.64 × 10.sup.-3 2.53 × 10.sup.-4 1.2 × 10.sup.-5300 7.0 × 10.sup.-5 1.69 × 10.sup.-2 9.36 × 10.sup.-3 3.86 × 10.sup.-4 1.5 × 10.sup.-5310 9.0 × 10.sup.-5 2.60 × 10.sup.-2 1.30 × 10.sup.-2 5.83 × 10.sup.-4 2.0 × 10.sup.-5320 1.0 × 10.sup.-4 3.96 × 10.sup.-2 1.81 × 10.sup.-2 8.71 × 10.sup.-4 2.5 × 10.sup.-5330 2.0 × 10.sup.-4 5.95 × 10.sup.-2 2.49 × 10.sup.-2 1.29 × 10.sup.-3 3.1 × 10.sup.-5340 2.0 × 10.sup.-4 8.86 × 10.sup.-2 3.40 × 10.sup.-2 1.89 × 10.sup.-3 3.9 × 10.sup.-5350 3.0 × 10.sup.-4 1.31 × 10.sup.-1 4.60 × 10.sup.-2 2.73 × 10.sup.-3 4.8 × 10.sup.-5__________________________________________________________________________
It is well known that when the conventional neutralizer ammonia is used, the resulting ammonium salts can precipitate before the initial condensation temperature is reached. The point at which they precipitate is a function of the equilibrium vapor pressure of the salt. By comparing the vapor pressures of various amine salts at selected temperatures with the vapor pressure of the ammonium salt, a precipitation potential for each amine salt is determined based on the precipitation potential of the ammonium salt. Table II shows the precipitation potential of certain select amine salts. It is quite evident that those amine salts having the lowest precipitation potential (below the ammonium salt) are those formed from amines having a pKa of between 5 and 8.
TABLE II__________________________________________________________________________Amine Salt Precipitation Potential V.P. (ATM) V.P. (ATM) @ 300° F. @ 225° F. PrecipitationAmine Chloride Salt pKa (95% Confidence Interval) Potential*__________________________________________________________________________Ethylenediamine HCl 10.7 1.6-4.6 × 10.sup.-7 1.9-5.6 × 10.sup.-8 140.0Ethanolamine HCl 9.50 2.5-4.5 × 10.sup.-6 2.9-5.3 × 10.sup.-7 13.0Morpholine HCl 8.33 1.2-1.9 × 10.sup.-5 1.6-2.6 × 10.sup.-6 2.5NH.sub.3 .HCl 9.35 5.5-8.0 × 10.sup.-5 3.1-4.4 × 10.sup.-6 1.0Methylmorpholine HCl 7.14 3.2-4.8 × 10.sup.-4 1.0-1.5 × 10.sup.-5 0.20Ethylmorpholine HCl 7.60 3.0-4.2 × 10.sup.-4 1.1-1.6 × 10.sup.-5 0.24Pyridine Base A** HCl 6.0 1.2-1.9 × 10.sup.-3 1.1-1.7-10.sup.-4 0.035Pyridine HCl 5.25 0.9-1.0 × 10.sup.-2 5.1-6.1 × 10.sup.-4 .0074-Picoline HCl 6.02 1.5-2.0 × 10.sup.-2 3.9-5.3 × 10.sup.-4 .0053-Picoline HCl 5.68 6.4-8.1 × 10.sup.-2 1.3-1.7 × 10.sup.-3 .0014__________________________________________________________________________ *Precipitation Potential = Average V.P. NH.sub.4 Cl/Average V.P. amine salt over the temperature range of 225°-300° F. **Pyridine Base A = 2picoline, 3picoline, 4picoline and pyridine
The neutralizing amines according to the present invention are effective at inhibiting the corrosion of the metallic surfaces of petroleum fractionating systems such as crude towers, trays within such towers, heat exchangers, receiving tanks, pumparounds, overhead lines, reflux lines, connecting pipes and the like. These amines may be added to the distillation unit at any of these points, the tower charge or at any other location in the overhead equipment system prior to the location where the condensate forms.
It is necessary to add a sufficient amount of the neutralizing amine compound to neutralize the acidic corrosion causing species. It is desirable that the neutralizing amine be capable of raising the pH of the initial condensate to 4.0 or greater. The amount of neutralizing amine compound required to achieve this objective is an amount sufficient to maintain a concentration of between 0.1 and 1,000 ppm, based on the total overhead volume. The precise neutralizing amount will vary depending upon the concentration of chlorides or other corrosive species. The neutralizing amines of the present invention are particularly advantageous in systems where chloride concentrations are especially high, and where a water wash is absent.
The absence of a water wash causes a system to have a lower dew point temperature than would be present if a water wash is used. The presence of a high chloride concentration necessitates the addition of a sufficient neutralizing amine to neutralize the hydrochloric acid. These factors increase the likelihood of an amine hydrochloride salt exceeding the equilibrium vapor pressure and depositing before the water dew point is reached.
An alternate method of using the low pKa amines is to blend them with more basic neutralizing amines such as methoxypropylamine, ethanolamine, morpholine and methylisopropylamine. There are several advantages which result from these blends, depending upon the parameters of the system to be treated, over using either class of amines alone.
One advantage is found in blending a minor amount of highly basic amine with a low pKa amine. These blends would be advantageous to use in systems where a subneutralizing quantity of highly basic amine can be used without causing above the water dew point corrosion and/or fouling problems. FIG. II demonstrates the benefit in neutralizing strength realized by blending a small amount of a highly basic amine with a low pKa neutralizing amine. Using a blend of mostly low pKa neutralizing amine reduces the amine salt deposition potential versus applying a neutralizing quantity of the highly basic amine.
A second benefit of blending low pKa neutralizing amines with highly basic neutralizing amines results from the buffering ability of the low pKa neutralizing amines. A highly basic amine such as methoxypropylamine or ethanolamine is not buffered in the desired pH control range. This is demonstrated in FIG. III. Using a traditional neutralizing amine in a system that is not naturally buffered, it is difficult to control pH at the commonly desired pH control range of 5-7. Adding a low pKa amine as a minor component gives considerable buffering in this pH range.
FIELD TRIAL
Neutralizing amines having a pKa of between 5 and 8 were evaluated at an Oklahoma refinery for the purpose of determining their efficacy at raising dew point pH. A neutralizing amine according to the present invention consisting of a blend of 85% 4-picoline and 15% 3-picoline was tested and compared with a conventional neutralizing amine, Betz 4H4 (a blend of highly basic amines), available from Betz Laboratories.
Conditions in the fractionator unit were as follows. The bottoms temperature was 668° F.±1°. Tower top pressure and temperature remained constant at 10.5 psig and 257±1°. Tower top pressure and temperature remained constant at 10.5 psig and 257±1° F., respectively. Total overhead flow varied little on a daily basis and averaged 10,850 barrels per day (BPD).
Water samples were collected using a Condensate On Line Analyzer (COLA) and from the system accumulator. The COLA is a device that hooks up to an overhead vapor line and passes these vapors through a vessel that collects condensed naphtha and/or water. Cooling water can be applied to the COLA to cool the vapors further and increase condensation. The COLA was used without the presence of cooling water in order to obtain samples as close to the dew point of water as possible. The temperature in the COLA was measured to be between 200° F. and 207° F.
The neutralizer was fed continuously into the overhead prior to the overhead condensing system. The feed rate was varied and is shown in Table III and IV, below. It is indicated in gallons per day and is within the previously noted concentration range of 0.1 to 1,000 ppm. When the low pKa amine was blended with a minor amount (less than 20% of treatment) of the highly basic amine, excellent dew point pH elevation was achieved.
TABLE III______________________________________Comparison Between Betz 4H4 and a blended Picoline(70% aqueous solution of 4-Picoline, 15% 3-Picoline) on pH Feed Rate Dew PointNeutralizer (GPD) pH Accumulator pH______________________________________None -- 4.8 4.54H4 2.0 8.3 5.34H4 4.1 8.7 5.64H4 9.0 9.8 6.3Blended Picoline 6.2 5.2 5.3Blended Picoline 12.5 5.3 5.4Blended Picoline 18.4 6.6 5.4Blended Picoline 30 6.0 5.6______________________________________
TABLE IV______________________________________Mixed 4H4 and Blended Picoline (as in TABLE III)Feed Feed RateRate (GPD) % Active 4H4/ Dew Accu-(GPD) Blended % Active Blended Point mulator4H4 Picoline Picoline pH pH______________________________________1.1 6.0 8%/92% 7.8 5.62.1 10.9 8%/92% 8.9 ± 1 5.7 ± .11.0 1.8 20%/80% 7.0 5.22.0 3.5 20%/80% 8.7 5.6______________________________________
The desired pH elevation at the point of initial condensation was achieved with the picoline alone. However, a much higher pH results when the low pKa amines are blended with a minor amount of a highly basic neutralizer. The blends may be utilized very effectively in distillation systems where chloride upsets occur regularly or no water wash is employed. Additionally, these formulations may be useful in treating crude feedstocks which contain high amounts of acidic species. | A process for adding an amine having a pKa of between 5 and 8 to a petroleum refinery distillation unit for the purpose of neutralizing acidic species contained in the hydrocarbon feedstock. The use of these amines raises the dew point pH sufficiently to prevent corrosion of the metallic surfaces of the overhead equipment while reducing the potential for the precipitation of amine salts. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to glucose regulation of fatty acid synthesis and, more particularly, to a glucose-inducible human fatty acid synthase mRNA binding protein.
[0002] Long chain fatty acids are necessary for normal cellular structure and function. De novo synthesis represents an important source of these fatty acids. Critical to this process is the enzyme fatty acid synthase (FAS), a multifunctional protein which synthesizes saturated fatty acids (mostly palmitate) from acetyl-CoA, malonyl-CoA, and NADPH. FAS is believed to be involved in the pathogenesis of such diverse disorders as atherosclerosis and malignancies. FAS overexpression is associated with hypertriglyceridemia, a common disorder predisposing to atherosclerosis. High levels of FAS predict a poor prognosis in humans with breast cancer.
[0003] (NOTE: Literature references on the following background information and on conventional test methods and laboratory procedures well-known to the ordinary person skilled in the art, and other such state-of-the-art techniques as used herein, are indicated by reference numerals in parentheses, and appended at the end of the specification).
BACKGROUND OF THE INVENTION
[0004] Chronically elevated concentrations of glucose like those seen in humans with diabetes mellitus are probably toxic. Insulin is important for glucose transport in certain tissues, but the majority of glucose uptake is independent of insulin and proportional to circulating glucose concentrations ( 6 ). In insulin-resistant states such as Type II diabetes, the total flux of glucose across certain tissues such as the liver is substantially increased. Glucose alone, independent of hormonal derangements, likely contributes to complications of diabetes such as hyperlipidemia ( 33 ).
[0005] Exactly how glucose promotes hyperlipidemia is unknown. The liver is central to this process and carbohydrates increase the expression of several hepatic genes involved in intermediary metabolism and lipogenesis including fatty acid synthase, L-type pyruvate kinase, acetyl-CoA carboxylase, ATP-citrate lyase, and malic enzyme ( 10 ). This effect is primarily transcriptional but glucose also stabilizes mRNAs for many feeding-responsive hepatic genes ( 32 ). Glucose promotes the stability of the message for the insulin receptor ( 12 ), another protein central to fuel flow and lipid metabolism.
[0006] Regulation of mRNA stability is an important mechanism for altering mammalian gene expression. Messenger RNA half-life depends on at least three components:
[0007] 1) The enzymes which degrade mRNA;
[0008] 2) Cis determinants located anywhere in the mRNA but usually in the 3′ terminus of the message; and
[0009] 3) Trans-acting factors which interact with the message to promote or prevent decay.
[0010] There are probably a small number of eukaryotic ribonucleases ( 20 ). It is likely that regulated message stability depends on the interaction of binding proteins with specific RNA sequences to either promote or prevent access to ribonucleases.
[0011] Fatty acid synthase (FAS) is the cytosolic enzyme that synthesizes palmitate from acetyl-CoA, malonyl-CoA, and NADPH ( 36 ). It is rate-limiting in the long-term control of fatty acid synthesis ( 35 ) and regulated by several different classes of nutrients ( 8 ). FAS overexpression occurs in animal models of obesity ( 16 ). Carbohydrates stimulate FAS expression and produce hypertriglyceridemia in animals and humans ( 35 , 15 ).
[0012] FAS is also relevant to malignancy. Cultured carcinoma cells maintain high levels of endogenous fatty acid synthesis even in the presence of high concentrations of exogenous fatty acids ( 24 ). FAS overexpression in breast and prostate carcinomas is a powerful predictor of a poor clinical outcome ( 1 , 9 ). The enzyme is overexpressed in colorectal tumors ( 27 ). Glucose transport and catabolism are enhanced in cancer cells ( 28 ) suggesting that coordinate regulation of glucose and lipid metabolism characterize the malignant state.
[0013] Glucose alone, independent of hormones, stabilizes the FAS message in HepG2 cells ( 32 ). In this model system, glucose maintains message levels for several hours while decay is rapid following glucose deprivation ( 31 ).
BRIEF DESCRIPTION OF THE INVENTION
[0014] In accordance with the invention, it has been found that glucose induces the binding of a novel 178 kDa protein to the fatty acid synthase (FAS) message. This glucose-inducible human FAS mRNA binding protein has been purified to homogeneity and its binding element defined. This large phosphoprotein binds to a novel repetitive element in the 3′ untranslated region (UTR) of the FAS mRNA. In particular, the binding has been mapped to a 37 nucleotide stretch within the first 65 bases of the 3′ UTR of mRNA.
[0015] Purification and characterization of the novel 178 kDa protein of the invention herein was carried out in conjunction with a determination of the underlying mechanisms whereby glucose stabilizes the mRNA for FAS and its relationship to diverse human disorders, including hyperlipidemia, obesity and malignancy.
[0016] More specifically, as described hereinbelow in greater detail:
[0017] RNA gel mobility shift assays were used to demonstrate that human HepG2 cells and bovine liver contain a cytoplasmic factor which binds specifically to the 3′ terminus of the human FAS mRNA.
[0018] D-glucose increased RNA binding activity by 2.02-fold (p=0.0033) with activity peaking three hours after glucose feeding.
[0019] Boiling or treatment of extracts with proteinase K abolished binding.
[0020] UV crosslinking of the FAS mRNA-binding factor followed by SDS-PAGE resolved a proteinase K-sensitive band with an apparent molecular mass of 178±7kD.
[0021] The protein was purified to homogeneity using nondenaturing polyacrylamide gels as an affinity matrix.
[0022] Acid phosphatase treatment of the protein prevented binding to the FAS mRNA, but binding activity was unaffected by modification of sulfhydryl groups and was not Mg ++ -or Ca ++ -dependent.
[0023] Deletion and RNase T 1 mapping localized the binding site of the protein to 37 nucleotides characterized by the repetitive motif ACCCC and found within the first 65 bases of the 3′ UTR.
[0024] Hybridization of the FAS transcript with an oligonucleotide antisense to this sequence abolished binding.
[0025] These findings indicate that a 178 kD glucose-inducible phosphoprotein binds to an (ACCCC) n -containing sequence in the 3′ UTR of the FAS mRNA within the same time frame that glucose stabilizes the FAS message. This protein is thus believed to participate in the post-transcriptional control of FAS gene expression.
DETAILED DESCRIPTION OF THE INVENTION
[0026] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the present invention, it is believed that the invention will be better understood from the following preferred embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 shows gel mobility shift assays that identify a cytosolic HepG2 factor binding specifically to the 3′ terminus of the human FAS mRNA.
[0028] A radiolabeled transcript containing the distal coding region and the first 400 bases of the 3′ UTR for the FAS mRNA (transcript 3 of FIG. 6) was generated by in vitro transcription.
[0029] For each lane, 10 μg of HepG2 S100 cytosolic extract was incubated with radiolabeled sense FAS RNA followed by treatment with RNase T 1 and electrophoresis in non-denaturing gels.
[0030] Incubations were performed in the presence (lanes 3 - 5 and 7 - 12 ) and absence (lanes 1 , 2 , 6 ) of nonradioactive competitor RNA.
[0031] The position of the gel-shifted band is indicated by arrowheads. The position of free, RNase T 1 -digested probe is indicated at the bottom of the gel.
[0032] Lane 1 contained probe only (P) without extract.
[0033] Lanes 3 - 5 represent incubations performed in the presence of a 1-10 fold molar excess of nonradioactive FAS sense RNA.
[0034] Lanes 7 - 9 represent incubations performed in the presence of a 1-10 fold molar excess of nonradioactive FAS antisense RNA.
[0035] Lanes 10 - 12 represent incubations performed in the presence of a 1-10 fold molar excess of nonradioactive lipoprotein lipase sense RNA.
[0036] [0036]FIG. 2, in three parts, A, B, and C, shows that binding of the FAS mRNA binding factor is induced by D-glucose.
[0037] [0037]FIG. 2A shows the results of a representative gel mobility shift assay comparing RNA binding activity of equal amounts of HepG2 cytosolic extract (within the linear response range of the assay) at time zero (lane 2 ), and three hours after feeding 4500 mg/L D-glucose (lane 3 ) or the same concentration of L-glucose (lane 4 ).
[0038] [0038]FIG. 2B shows the results of three independent experiments identical to FIG. 2A as quantitated by densitometry. Binding activity (in arbitrary units, mean±sem) of the gel-shifted band was 14.95±1.20 for D-glucose and 7.40±0.18 for L-glucose (p=0.0033).
[0039] [0039]FIG. 2C shows the results of a representative time course experiment. Extracts were prepared at various times following treatment with 4500 mg/ml D- or L-glucose, subjected to gel shift assays, and results were quantitated by densitometry.
[0040] [0040]FIG. 3, in two parts, A and B, shows that the FAS mRNA binding factor is a protein.
[0041] For FIG. 3A, lanes contained radiolabeled FAS RNA in the absence (lane 1 ) or presence (lanes 2 - 4 ) of 20 μg of HepG2 cytosolic protein.
[0042] HepG2 extracts were subjected to no treatment (lane 2 ), incubation with 500 μg/ml proteinase K at 37° C. for one hour (lane 3 ), or heating at 100° C. for 5 min. (lane 4 ) prior to the addition of FAS RNA.
[0043] Another band of faster mobility is seen just below the dominant band indicated by the arrowhead in lane 2 . This lower band likely represents a proteolytic fragment of the upper band as described in the text.
[0044] Free, RNase T 1 -digested probe appears in each lane along the bottom of the gel.
[0045] For FIG. 3B, gel mobility shift assays were performed using multiple lanes of native gels. Gels were UV crosslinked, then bands denoted by the arrowhead in FIG. 3A were cut out and either directly subjected to SDS-PAGE in a 6% gel (lane 1 ) or treated with 500 μg/ml proteinase K at 37° C. for, one hour before electrophoresis (lane 2 ). Appropriate regions of native gels loaded with lysis buffer instead of HepG2 extracts were also cut out and electrophoresed (lane 3 ). The arrowhead shows the 178 kD position.
[0046] [0046]FIG. 4 shows the purification of the 178 kD FAS mRNA binding protein. HepG2 extracts were processed as described in Methods hereinbelow.
[0047] Protein yields at each step of the purification are shown in Table 1, hereinbelow.
[0048] Lanes 2 - 4 were loaded with 20 μg of protein per lane.
[0049] Lane 5 represents 10 μg of purified protein as determined by comparison with standards.
[0050] Lanes 1 - 5 represent amido black B staining of a 2-15% gradient gel.
[0051] Lane 6 is an autoradiograph of the same gel depicted in lane 5 . The 178 kD position is indicated by the arrowhead.
[0052] [0052]FIG. 5 shows that the FAS mRNA binding protein is a phosphoprotein.
[0053] Partially purified protein was incubated in the absence (No Phosphatase) or presence of increasing concentrations of potato acid phosphatase followed by gel shift assay and quantitation by densitometry.
[0054] The experiment included a tube containing the highest concentration of potato acid phosphatase (0.36 units) in the presence of 10 μM okadaic acid.
[0055] Asterisks indicate that binding activity in the presence of both 0.24 units (p<0.01) and 0.36 units (p<0.001) of phosphatase was significantly different from activity in the absence of phosphatase.
[0056] Results represent the mean±sem of three independent experiments.
[0057] The inset shows the results of a representative experiment:
[0058] lane 1 =No phosphatase,
[0059] lane 2 =0.09 units,
[0060] lane 3 =0.24 units,
[0061] lane 4 =0.36 units,
[0062] lane 5 =0.36 units+okadaic acid.
[0063] [0063]FIG. 6 shows transcripts used to localize the binding element for the 178 kD protein.
[0064] Results of gel shift assays for the 178 kD protein are shown on the right (RNA binding Activity in %).
[0065] Binding activity was quantitated by densitometry and normalized to the signal for transcript 3 .
[0066] Each transcript was assayed at least 3 times.
[0067] The signals generated by transcripts 1 and 3 were not significantly different (p=0.2976, n=4).
[0068] The difference between transcripts 3 and 7 was significant (p<0.0001, n=3).
[0069] The positions of the stop codon (UAG) and polyadenylation signal (AUUAAA) are indicated.
[0070] Transcript 2 had no RNA binding activity. Transcripts antisense to transcripts 1 , 3 , 4 , and 5 as well as a sense lipoprotein lipase transcript also had no RNA binding activity.
[0071] [0071]FIG. 7, in two parts, A and B, shows the identification of the binding element for the 178 kD protein by RNase T 1 mapping and oligonucleotide competition.
[0072] For FIG. 7A, gel shift assays were performed with transcripts 4 and 5 from FIG. 6. RNA protein complexes were excised, eluted, extracted with phenol/chloroform, and precipitated.
[0073] RNA was incubated in the presence (lanes 2 and 4 ) or absence (lanes 1 and 3 ) of RNase T 1 , then separated on 15% denaturing polyacrylamide gels and autoradiographed.
[0074] Lanes 1 - 2 show results using transcript 4 , and lanes 3 - 4 show results using transcript 5 from FIG. 6.
[0075] Identical results were also obtained using transcript 3 from FIG. 6.
[0076] Nucleotide size markers are shown to the left of the FIG. 7A panel and the position of the 37 nucleotide protected fragment is indicated by the arrowhead.
[0077] For FIG. 7B, gel shift assays were performed using HepG2 extracts and transcript 4 from FIG. 6 in the presence of competitor oligonucleotides as described in Methods, hereinbelow.
[0078] Oligo # 1 was antisense to the 37 nucleotides identified in FIG. 7A.
[0079] Oligos # 2 and # 3 were unrelated control sequences.
[0080] Lanes 1 - 6 show results of gel shift assays in the presence of increasing amounts of oligonucleotides.
[0081] Oligos were added in the following amounts:
[0082] Lane 1 =0 ng
[0083] Lane 2 =4.5 ng
[0084] Lane 3 =9 ng
[0085] Lane 4 =18 ng
[0086] Lane 5 =180 ng
[0087] Lane 6 =900 ng.
[0088] [0088]FIG. 8 shows the predicted structure of the 178 kD binding element.
[0089] Transcript 8 from FIG. 6 contains 126 nucleotides which were folded using the RNA secondary structure program of Michael Zuker, Washington University School of Medicine, at www.ibc.wustl.edu/˜zuker/rna/forml.cgi.
[0090] The predicted free energy for this structure is −43.2 kcal/mol.
[0091] This program predicts one other potential structure which was not consistent with the RNase T 1 mapping data.
[0092] The binding element is indicated by the arrow.
[0093] Points of RNA hybridization are indicated by solid circles.
[0094] The location of the stop codon (UAG) and the first base of the 3′ UTR are also indicated.
[0095] In order to illustrate the invention in further detail, the following specific laboratory examples were carried out. Although specific examples are thus illustrated herein, it will be appreciated that the invention is not limited to these specific, illustrative examples or the details therein.
EXAMPLES
Methods
[0096] Tissue Culture Reagents and Culture Conditions. Glucose-free/bicarbonate-free RPMI-1640, bicarbonate, D-glucose, L-glucose, and bovine serum albumin (BSA, fraction V) were purchased from Sigma. Fetal bovine serum (FBS) was purchased from Intergen. MEM was provided by the Washington University Tissue Culture Support Center.
[0097] HepG2 cells were grown in MEM+10% FBS for large scale preparation of cell extracts and protein purification. For experiments involving glucose regulation, cells were treated as described ( 31 , 32 ). HepG2 cells are human hepatoma cells widely distributed throughout the world and have been readily available to the public without restriction for many years from the depository of the American Type Culture Collection, Rockville, Md.
[0098] On day 3 or 4 after passage, cells were fed MEM+10% FBS. On day 5 or 6, culture medium was replaced with RPMI-1640+10% FBS+4500 mg/L D-glucose. Twenty-four hours later, medium was removed and dishes were washed twice with phosphate-buffered saline (PBS) at 37° C. The cells were then fed RPMI-1640+3% BSA+4500 mg/ml D-glucose.
[0099] Six hours later, the medium was removed and dishes were washed twice with PBS at 37° C. Cells were then fed RPMI-1640+3% BS with 4500 mg/L D-glucose or 4500 mg/L L-glucose.
[0100] Preparation of S100 Cytosolic Extracts. For HepG2 cells, medium was removed and dishes were washed twice with PBS at 4° C. The cells were scraped in lysis buffer (250 μl/100 mm dish) consisting of 10 mM Tris (pH 7.4), 40 mM KCl, 0.15 mM spermine, 2 mM EDTA, 5 mM dithiothreitol, and 100 μg/ml phenylmethylsulfonyl fluoride. Cells were homogenized using a Dounce homogenizer by twenty strokes of a tight-fitting pestle. Nuclei were removed by centrifugation at 13,000 g for ten min. This supernatant was centrifuged at 100,000 g for one hour in a Beckman TL-100 ultracentrifuge to yield a polysome-free extract (S100). Protein concentration was determined using the BCA Protein Assay (Pierce).
[0101] Bovine liver was obtained from a local slaughterhouse (Schneider Packing Co., St. Louis). Immediately after sacrifice, livers were placed in a plastic bag and packed in ice. At the lab, livers were perfused with saline to remove blood then homogenized in lysis buffer using a Waring blender. Nuclei were sedimented and then the supernatant was spun at 100,000 g to yield a polysome-free extract.
[0102] Preparation of RNAs by In Vitro Transcription. The parent plasmid used as a template for transcription of the FAS full-length 3′ untranslated region (UTR) was constructed by subcloning an Nco I-Not I restriction fragment of the human FAS cDNA (from nucleotides 1190 to 2237 as numbered in reference 31 ) into pGEM-5Z. This fragment (FIG. 6, transcript 1 ) contained the coding region for the 72 carboxyl-terminal amino acids of the FAS protein and the entire, 806 bases of the 3′ UTR. Several additional FAS plasmids (see FIG. 6) were derived from this construct by standard cloning techniques. Templates were linearized and gel-purified before in vitro transcription.
[0103] Radiolabeled FAS RNA probes were prepared using T7 RNA polymerase (sense) or SP6 (antisense) and 32 P-CTP and purified using NucTrap columns (Stratagene) before use in gel mobility shift assays. Nonradioactive transcripts used for competition studies were prepared in the same way except unlabeled CTP was used for transcription reactions. The plasmid used as a template for transcription of a portion of the coding region of the lipoprotein lipase message has previously been described by Seip et al ( 30 ).
[0104] All of the RNAs generated by in vitro transcription were treated identically. Probes were frozen at −70° C. immediately following their preparation. The transcripts were thawed gradually at room temperature prior to use in gel mobility shift assays.
[0105] Gel Mobility Shift Assays. Binding reactions were performed with S100 cytosolic extract and 0.5-1.0×10 5 cpm of 32 P-labeled RNA in binding buffer (10 mM Tris [pH 7.4], 2 mM EDTA, 40 mM KCl, and 5 mM dithiothreitol). For competition experiments, competitor transcripts, polyribonucleotides, or oligonucleotides were added before the addition of labeled RNA.
[0106] Binding reactions were incubated for 10 min. at 4° C. Five units of RNase T 1 , which degrades single-stranded RNA not bound to protein, was then added and the incubation was continued for 10 min. at room temperature. The binding reactions were then subjected to electrophoresis through a 6% nondenaturing polyacrylamide gel. Gels were autoradiographed at −70° C. for 4-24 hours.
[0107] Ultraviolet Crosslinking of the RNA-Protein Complex. Multiple lanes of 6% non-denaturing gels were loaded with the products of binding reactions, some of which contained radiolabeled RNA only. Following electrophoresis, gels were UV irradiated at 270,000 μJ/cm 2 .
[0108] Gels were autoradiographed, then radiolabeled bands were excised from lanes loaded with extracts; corresponding gel regions were also excised from lanes run with RNA only. Samples were pooled and incubated in an equal volume of Laemmli electrophoresis buffer at 50° C. for 30 min. then at 100° C. for one hour. Eluates from lanes containing extracts were separated into two aliquots, one of which was treated with proteinase K and one of which was not. Samples were subjected to SDS-PAGE in 6% gels then autoradiographed at −70° C.
[0109] Size Exclusion Chromatography. S100 cytosolic extracts from either HepG2 cells or bovine liver were precipitated with 25-45% ammonium sulfate. After dialysis against lysis buffer, samples were loaded onto Superose 6 columns equilibrated with 0.9 M NaCl+0.2 mM EDTA+0.2 g/L NaN 3 . Fractions of 0.5 ml were collected at a flow rate of 0.4 ml/min and assayed for RNA binding activity by gel mobility shift assay.
[0110] Ion Exchange Chromatography. Following ammonium sulfate fractionation, samples were applied to prepacked anion (Mono Q) or cation exchange columns (Mono S) using a Pharmacia FPLC.
[0111] For the Mono S column, both 50 mM malonate (pH 5.0) and 50 mM MES (pH 6.0) were used for column equilibration in separate experiments. For the Mono Q column, equilibration was performed using 20 mM Tris (pH 7.5); the elution buffer was 20 mM Tris; (pH 7.5)±0−1.0 M KCl.
[0112] For both ion exchange columns, the flow rate was 0.5 ml/min and collected fractions were assayed for RNA binding activity. The binding protein did not bind to a Mono S column under a variety of conditions. The protein did bind to a Mono Q column and was eluted with 0.3 M KCl at pH 7.5.
[0113] RNA Binding Protein Purification. In a typical purification, S100 cytosolic extracts were prepared from approximately 10 9 HepG2 cells. After fractionation with 25-45% ammonium sulfate and dialysis, samples were subjected to anion exchange chromatography as described above.
[0114] Fractions containing the RNA binding protein were pooled, concentrated with Centricon-30 fibers at 5000 g, then subjected to a large scale gel shift procedure using 40-45 nondenaturing polyacrylamide gels.
[0115] Bands were cut out and placed into an electroelution apparatus (BioRad model 422). Elution was performed at 10 mA/glass tube for 5 hours in 1 X TBE. Samples were desalted using Centricon filters then subjected to SDS-PAGE using 2-15% gradient gels. Gels were stained with amido black B followed by autoradiograph at −70%.
[0116] Dephosphorylation of the RNA Binding Protein. S100 extracts were subjected to ammonium sulfate fractionation and anion exchange chromatography. Partially purified protein was incubated with potato acid phosphatase (Boehringer Mannheim) in MOPS (pH 6.5), 1 mM MgCl 2 , 100 mM KCl, 0.2 mM leupeptin for 30 minutes at 30° C. as described by Kwon and Hecht ( 17 ). The phosphatase inhibitor okadaic acid (10 μM) was added to some samples before the incubation.
[0117] RNase T 1 Mapping. Gel mobility shift assays were performed using the 25-45% ammonium sulfate fraction from HepG2 cells. Bands were cut from the gel and electroeluted as described above.
[0118] Samples were extracted with phenol/chloroform then ethanol precipitated. Radioactive RNA (˜10,000 cpm) was separated into two aliquots, one of which was digested with 20 units of RNase T 1 at room temperature for 30 min. The second aliquot was sham digested. Samples were then separated on a 15% denaturing polyacrylamide gel with end-labeled size markers and autoradiographed.
[0119] Oligonucleotide Competition. Radiolabeled RNA was heated to 75° C. for 10 min., a competitor oligonucleotide (oligo # 1 , # 2 or # 3 ) at various concentrations was added, and the mixture was gradually cooled to room temperature over 30-60 min. to allow hybridization of the oligonucleotide with the RNA transcript.
[0120] The RNA:DNA hybrid was then incubated with HepG2 extracts and assayed for gel shift activity. The sequences of the competitor oligos were:
Oligo #1- GGGGGTGGGG TGGGGTGGGG TGGGGATGGT GGAGTGA [SEQ ID NO:1] Oligo #2- GATCTAGCTT CCCGCTGATG AGTCCGTGAG GACGAAACAT GCCGGCA [SEQ ID NO:2] Oligo #3- GATCTGCCGG CATGTTTCGT CCTCACGGAC TCATCAGCGG GAAGCTA [SEQ ID NO:3]
RESULTS
[0121] When HepG2 extracts were incubated with a transcript corresponding to the FAS 3′ terminus, a discrete band was seen in RNA gel shift assays (FIG. 1, lane 2 ) that did not appear with RNA alone (lane 1 ).
[0122] The addition of a 10-fold molar excess of nonradioactive FAS sense transcript essentially eliminated the gel shift signal (lane 5 ) while nonradioactive FAS antisense (lane 10 ) and LPL sense (lane 12 ) transcripts had no effect. Identical results were seen in five independent experiments.
[0123] In other experiments, the addition of up to a 100-fold molar excess of the FAS antisense and LPL sense transcripts had no effect on binding. No complexes were seen when HepG2 extracts were incubated with radiolabeled lipoprotein lipase RNA.
[0124] Polyribonucleotides did not compete with 32 lP-labeled FAS RNA for binding. In two independent experiments, a 100-fold molar excess of FAS sense transcript eliminated binding but the same molar excess of polyadenylic acid, polyuridylic acid, polyguanidylic acid and polycytidylic acid had no effect.
[0125] Binding activity was also present in cytoplasmic extracts from bovine liver. It was originally intended to purify and characterize the protein from bovine liver since it was readily available, but levels of expression were lower in cow liver than HepG2 cells and the latter were easier to manipulate.
[0126] The intensity of the gel-shifted band was dependent on the input protein in the assay. In five independent experiments, band intensity increased linearly with protein concentrations from 5 to 20 μg.
[0127] Glucose regulates the expression of the FAS mRNA-binding factor (FIG. 2). When cells were cultured in serum-free medium, D-glucose (FIG. 2A, lane 3 ) but not L-glucose (FIG. 2A, lane 4 ) increased binding activity in gel shift assays. At the three-hour time point in three independent experiments using protein concentrations within the linear response range of the assay, binding intensity (arbitrary units, mean±sem) as shown in FIG. 2B was 14.95±1.20 with D-glucose and 7.40±0.18 for L-glucose (p=0.0033 by unpaired, two-tailed t test).
[0128] The Time course for the glucose-induced increase in binding is shown in the representative experiment of FIG. 2C. After feeding 4500 mg/L D-glucose, binding intensity increased by one hour and peaked at 3 hours. The return to baseline was variable, occurring between 6 hours and 11 hours after feeding. L-glucose had no effect. Results were confirmed in three independent experiments.
[0129] Treatment of HepG2 extracts with proteinase K or boiling abolished the binding activity (FIG. 3A). The same results were seen in three independent experiments.
[0130] Lane 2 of FIG. 3A shows a dominant upper band (denoted by the arrowhead) as well as a lower band with faster mobility. This lower band probably represents a degradation product. It was faint in fresh extracts and increased in intensity over time.
[0131] The band at the arrowhead in FIG. 3A was resolved by SDS-PAGE after UV crosslinking as described in Methods, hereinbefore. Bands were cut from multiple lanes, eluted, pooled, and electrophoresed in SDS gels (FIG. 3B). The FAS mRNA-binding protein (arrowhead, FIG. 3B, lane 1 ) analyzed under these conditions had an apparent molecular mass of 178±7 kD (mean±sem of four independent experiments).
[0132] In two of the four experiments, despite the fact that only the upper, dominant band was cut from native gels, SDS-PAGE showed a lower molecular weight protein just below the 178 kD band consistent with the hypothesis that the pattern sometimes seen in gel shift assays is due to proteolysis. The 178 kD signal did not appear when eluted bands were treated with proteinase K before SDS-PAGE (FIG. 3B, lane 2 ) and was absent from lanes without extracts (lane 3 ).
[0133] Since the apparent size as determined by SDS-PAGE included crosslinked ribonucleotides, the molecular weight of the FAS RNA binding protein was also determined by gel filtration chromatography as described in Methods, hereinbefore. Using either HepG2 or bovine liver extracts, the fractions with RNA binding activity eluted at an apparent molecular weight of 160-170 kD.
[0134] The protein was purified as described in Methods, hereinbefore, from HepG2 S100 extracts by a combination of ammonium sulfate precipitation, anion exchange chromatography and an affinity step. Instead of making an RNA affinity column, nondenaturing polyacrylamide gels were used as the chromatography matrix.
[0135] Preparative scale gels were Uv crosslinked and autoradiographed, then bands representing the RNA binding protein were excised and electroeluted. Results of a typical purification are shown in FIG. 4. Protein yields at each step of the purification are shown in Table 1. In FIG. 4, lane 6 is an autoradiograph of the purified protein from lane 5 . The protein is visible after autoradiography because radiolabeled FAS RNA was UV crosslinked to the protein during purification. The same results were seen in four independent purifications.
[0136] Purification of the 178 kD protein allowed defining of its properties. Phosphorylation is required for the activity of some RNA binding proteins ( 17 , 19 ). Acid phosphatase decreased binding activity of Mono Q-purified protein in a dose-dependent fashion, an effect that was reversed with the phosphatase inhibitor okadaic acid (FIG. 5). Results in FIG. 5 represent the mean±sem of three independent experiments.
[0137] The iron responsive protein ( 14 ), the AU binding factor ( 19 ) and a protein which binds to the c-myc message ( 26 ) represent examples of RNA binding proteins which require intact sulfhydryl groups for binding activity.
[0138] To test the role of sulfhydryl groups in the activity of the human FAS mRNA binding protein, Mono Q-purified protein was treated with the SH-oxidizing agent diamide (0-10 mM) or the SH-alkylating agent NEM (N-ethylmaleimide, 0-2 mM) in the presence or absence of DTT. In three independent experiments, modification of sulfhydryl groups had virtually no effect on RNA binding activity.
[0139] Divalent cations are required by some RNA binding proteins ( 19 ). In four independent experiments using Mono Q-purified protein, magnesium concentrations between 0 and 4 mM and calcium concentrations between 0 and 2 mM had no effect on gel shift activity.
[0140] Another important property of the 178 kD protein is its binding element. A series of deletion plasmids were constructed and used to generate transcripts for gel shift assays (FIG. 6). Binding activity was normalized to the signal for transcript 3 in FIG. 6. The transcript representing the entire 3′ terminus of the message (transcript 1 ) tended to have lower binding activity compared to transcript 3 (88±13 vs 100±2, p=0.2976).
[0141] Transcript 2 , representing the distal 3′ UTR, had no binding activity. Transcripts antisense to transcripts 1 , 3 , 4 , and 5 also had no binding activity. Activity for transcript 7 was 6% of the activity of transcript 3 (6±1 vs 100±2, p<0.0001). Full binding activity was retained by transcript 8 , a 126 nucleotide transcript containing the proximal 3′ UTR.
[0142] The specific sequence mediating high level binding activity was identified within the first 65 bases of the FAS 3′ UTR. RNase T 1 mapping using transcripts 4 and 5 from FIG. 6 identified a 37 nucleotide fragment (FIG. 7). The fragment did not contain internal Gs because RNase T 1 digestion of RNA isolated from bound protein had no effect on the migration of the isolated RNA (FIG. 7A, lanes 2 and 4 ). There is one G-free region of exactly 37 nucleotides within the FAS 3′ UTR. When an oligonucleotide antisense to this sequence (FIG. 7B, Oligo # 1 ) was hybridized to the FAS transcript, RNA binding activity was abolished. Two different control oligonucleotides had no effect.
[0143] The most likely secondary structure of transcript 8 from FIG. 6 is shown in FIG. 8 with the G-free binding element indicated by the arrow. The sequence of this element is:
[0144] UC-ACUCC-ACC-AUCCCC-ACCCC-ACCCC-ACCCC-ACCCCC. [SEQ ID NO: 4 ]
[0145] As described above, a large cytosolic protein which binds specifically to a repetitive ACCCC motif in the proximal 3′ UTR of the human FAS mRNA has been purified to homogeneity. Binding is induced by glucose and requires phosphorylation. Glucose deprivation leads to the rapid decay of FAS mRNA which is prevented by D-glucose feeding ( 31 ). Either glucose deprivation is associated with a factor promoting FAS mRNA decay, or glucose feeding is associated with a factor protecting the message from decay.
[0146] In the above examples, D-glucose increases 178 kD binding activity precisely within the time frame that D-glucose protects FAS mRNA from decay suggesting that this protein is a protective trans-acting mRNA-binding protein.
[0147] Several presumably protective mRNA-binding proteins are induced in response to nutritional or environmental signals. Iron deprivation induces iron responsive protein binding to the transferrin receptor 3′ UTR and protects the message from endonucleolytic attack ( 14 ).
[0148] Estrogens induce protein binding to the vitellogenin 3′ UTR in association with message stabilization ( 7 ). Hypoxia stabilizes the tyrosine hydroxylase mRNA and increases protein binding to its 3′UTR ( 5 ).
[0149] AUREs (repeated copies of the sequence AUUUA) are instability elements; several proteins bind AUREs in association with message stabilization ( 3 , 37 ). Tumor necrosis factor a stabilizes glucose transporter 1 (GLUT 1 ) mRNA and induces protein binding to a GC-rich region of the GLUT1 3′ UTR ( 20 ).
[0150] Exactly how protective RNA-binding proteins work is unknown. Binding may block the action of constitutive endonucleases at a critical site in the message. How cytoplasmic message is compartmentalized is poorly understood but the novel glucose-inducible protein described herein could alter FAS mRNA transport to prevent access to cytoplasmic decay complexes.
[0151] In the described system, polyribosomes protect FAS mRNA from decay after glucose deprivation ( 31 ) raising the possibility that the 178 kD protein promotes the association of the FAS message with the translational apparatus.
[0152] The binding activity described herein is believe to be novel, since there does not appear to be any previously reported mRNA binding proteins of similar size. The 178 kD binding element (ACCCC) n , appears to be unique. It resembles the AURE with cytidines substituted for uridines. Recent data suggest that UUAUUUAUU [SEQ ID NO: 5 ] may be the minimal sequence of the AURE conferring instability ( 38 ).
[0153] If the present element is analogous, the functional motif may be CCACCCCACC [SEQ ID NO: 6 ]; there are three overlapping copies of this sequence in the 178 kD binding element. Many RNA-binding proteins recognize polypyrimidines, but uridines, not cytidines, are generally preferred ( 22 ).
[0154] A 35 kD cytoplasmic protein that binds the β 2 -adrenergic receptor mRNA ( 25 ), and apobec-1, the cytidine deaminase that binds and edits apoB mRNA ( 2 ), are examples of RNA binding proteins completed by poly(U). Polyribonucleotides had no effect on the interaction of the 178 kD protein with the FAS mRNA (see Results, above). Mutagenesis of the (ACCCC), n motif and determining if this sequence can confer glucose-induced stability to unrelated messages will be critical for further characterizing its function.
[0155] More than a dozen classic metabolic enzymes have been shown to bind nucleic acids and dinucleotide binding domains common to these enzymes may be involved ( 13 ). The iron responsive protein is also an aconitase, catalyzing the conversion of citrate to isocitrate ( 11 ). Glyceraldehyde-3-phosphate dehydrogenase binds tRNA ( 34 ) and AUREs ( 23 ). Catalase binds and stabilizes its own mRNA ( 4 ).
[0156] From the above, it is seen how glucose can increase the binding of the 178 kD factor to the FAS mRNA. Phosphorylation is required for optimal binding (FIG. 5). It is believed that glucose metabolism induces phosphorylation of the 178 kD protein to promote binding to the FAS mRNA. It is known that glucose regulation of gene expression through phosphorylation occurs in yeast, whereby glucose initiates a complex phosphorylation cascade. Malate dehydrogenase ( 21 ) and the transcriptional activator SIP4 ( 18 ) are examples of yeast proteins differentially phosphorylated in response to glucose availability.
[0157] Glucose transiently increases binding of a large phosphoprotein to an ACCCC repetitive element in the 3′ UTR of the human FAS mRNA within the same time frame that glucose prevents FAS mRNA decay.
[0158] Since aberrant glucose and lipid metabolism are commonly associated, additional characterization of this protein could further link glycolysis and lipogenesis in such a way that mechanisms underlying such diverse disorders as diabetic dyslipidemia and malignancy are better understood.
TABLE 1 Purification of the Human FAS mRNA Binding Protein Purification Step Protein (mg) % Recovery S100 post-nuclear 280 100 cytoplasmic extract Ammonium Sulfate 42 15 Fractionation (25-45%) Mono Q column 4 1.4 Electroelution of 0.58 0.21 gel-shifted bands SDS-PAGE 0.01-0.02 0.004-0.007
[0159] Various other examples will be apparent to the person skilled in the art after reading the present disclosure without departing from the spirit and scope of the invention. It is intended that all such other examples be included within the scope of the appended claims.
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[0166] 7. Dodson, R. E., and D. J. Shapiro. An estrogen-inducible protein binds specifically to a sequence in the 3′ untranslated region of estrogen-stabilized vitellogenin mRNA. Mol. Cell. Biol. 14: 3130-3138, 1994.
[0167] 8. Dudek S. M., and C. F. Semenkovich. Essential amino acids regulate fatty acid synthase expression through an uncharged transfer RNA-dependent mechanism. J. Biol. Chem. 270: 29323-29329, 1995.
[0168] 9. Epstein, J. I., M. Carmichael, and A. W. Partin. OA-519 (fatty acid synthase) as an independent predictor of pathologic state in adenocarcinoma of the prostate. Urology 45: 81-86, 1995.
[0169] 10. Goodridge, A. G. Dietary regulation of gene expression: enzymes involved in carbohydrate and lipid metabolism. Annu. Rev. Nutr. 7: 157-185, 1987.
[0170] 11. Gray, N. K., S. Quick, B. Goosen, A. Constable, H. Hirling, L. Kuhn, and M. Hentze. Recombinant iron-regulatory factor functions as an iron-responsive-element-binding-protein, a translational repressor and an aconitase. Eur. J. Biochem. 218: 657-667, 1993.
[0171] 12. Hauguel-de-Mouzon, S., C. Mrejen, F. Alengrin, F., and E. Van Obberghen. Glucose-induced stimulation of human insulin-receptor mRNA and tyrosine kinase activity in cultured cells. Biochem. J. 305: 119-124, 1995.
[0172] 13. Hentze, M. W. Enzymes as RNA-binding proteins: a role for (di)nucleotide-binding domains? Trends Biochem. Sci. 19: 101-103, 1994.
[0173] 14. Hentze, M. W., T. Rouault, J. B. Harford, and R. D. Klausner. Oxidation-reduction and the molecular mechanism of a regulatory RNA-protein interaction. Science 244: 357-359, 1989.
[0174] 15. Hudgins L. C., M. Hellerstein, C. Seidman, R. Neese, J. Diakun, and J. Hirsch. Human fatty acid synthesis is stimulated by a eucaloric low fat, high carbohydrate diet. J. Clin. Invest. 97: 2081-2091, 1996.
[0175] 16. Jones, B. H., J. H. Kim, M. B. Zemel, R. P. Woychik, E. J. Michaud, W. O. Wilkison, and N. Moustaid. Upregulation of adipocyte metabolism by agouti protein: possible paracrine actions in yellow mouse obesity. Am. J. Physiol. 270: E192-E196, 1996.
[0176] 17. Kwon, Y. K., and N. B. Hecht. Binding of a phosphoprotein to the 3′ untranslated region of the mouse protamine 2 mRNA temporally represses its translation. Mol. Cell. Biol. 13: 6547-6557, 1993.
[0177] 18. Lesage, P., X. Yang, and M. Carlson. Yeast SNF 1 protein kinase interacts with SIP4, a C 6 zinc cluster transcriptional activator: a new role for SNF1 in the glucose response. Mol. Cell. Biol. 16: 1921-1928, 1996.
[0178] 19. Malter, J. S., and Y. Hong. A redox switch and phosphorylation are involved in the post-translational up-regulation of the adenosine-uridine binding factor by phorbol ester and ionophore. J. Biol. Chem. 266: 3167-3171, 1991.
[0179] 20. McGowan, K. M., S. Police, J. B. Winslow, and P. H. Pekala. Tumor necrosis factor-a regulationof glucose transporter (GLUTI) mRNA turnover. J. Biol. Chem. 272: 1331-1337, 1997.
[0180] 21. Minard, K. I., and L. McAlister-Henn. Glucose-induced phosphorylation of the MDH2 isozyme of malate dehydrogenase in Saccharomyces cerevisiae. Arch. Biochem. Biophys. 315: 302-309, 1994.
[0181] 22. Morris, D. R., T. Kakegawa, R. L Kaspar, and M. W. White. Polypyrimidine tracts and their binding proteins: regulatory sites for posttranscriptional modulation of gene expression. Biochemistry 32: 2931-2937, 1993.
[0182] 23. Nagy, E., and W. F. Rigby. Glyceraldehyde-3-phosphate dehydrogenase selectively binds AU-rich RNA in the NAD(+)-binding region (Rossman fold). J. Biol. Chem. 270: 2755-2763, 1995.
[0183] 24. Pizer, E. S., F. D. Wood, G. R. Pasterack, and F. P Kuhajda. Fatty acid synthase (FAS): a target for cytotoxic antimetabolites in HL60 promyelocytic leukemia cells. Cancer Res. 56: 745-751, 1996
[0184] 25. Port, J. D., L.-Y. Huang, and C. C. Malbon. P-adrenergic agonists that down-regulate receptor mRNA up-regulate a M r 35,000 protein(s) that selectively binds to P-adrenergic receptor mRNAs. J. Biol. Chem. 267: 24103-24108, 1992.
[0185] 26. Prokipcak, R. D., D. J. Herrick, and J. Ross. Purification and properties of a protein that binds to the C-terminal coding region of human c-myc mRNA. J. Biol. Chem. 269: 9261-9269, 1994.
[0186] 27. Rashid, A., E. S. Pizer, M. Moga, L. Z. Milgraum, M. Zahurak, G. R. Pastemak, F. P. Kuhajda, and S. R. Hamilton. Elevated expression of fatty acid synthase and fatty acid synthetic activity in colorectal neoplasia. Am. J. Path. 150: 201-208, 1997.
[0187] 28. Rempel, A., S. P. Methupala, and P. L. Pederson. Glucose catabolism in cancer cells: regulation of the Type II hexokinase promoter by glucose and cyclic AMP. FEBS Lett. 385: 233-237, 1996.
[0188] 29. Ross, J. Control of messenger RNA stability in higher eukaryotes. Trends Genetics 12: 171-175, 1996
[0189] 30. Seip R. L., T. J. Angelopoulos, and C. F. Semenkovich. Exercise induces human lipoprotein lipase gene expression in skeletal muscle but not adipose tissue. Am. J. Physiol. 268: E229-E236, 1995.
[0190] 31. Semenkovich C. F., T. Coleman, and F. T. Fiedorek Jr. Human fatty acid synthase mRNA: tissue distribution, genetic mapping, and kinetics of decay after glucose deprivation. J. Lipid Res. 36: 1507-1521, 1995.
[0191] 32. Semenkovich C. F., T. Coleman, and R. Goforth. Physiologic concentrations of glucose regulate fatty acid synthase activity in HepG2 cells by mediating fatty acid synthase mRNA stability. J. Biol. Chem. 268: 6961-6970, 1993.
[0192] 33. Semenkovich C. F., and J. W. Heinecke. The mystery of diabetes and atherosclerosis: time for a new plot. Diabetes 46: 327-334, 1997.
[0193] 34. Singh, R., and M. R. Green. Sequence-specific binding of transfer RNA by glyceraldehyde-3-phosphate dehydrogenase. Science 259: 365-368, 1993.
[0194] 35. Volpe, J. J., and P. R. Vagelos. Mechanisms and regulation of biosynthesis of saturated fatty acids. Physiol. Rev. 56: 339417, 1976.
[0195] 36. Wakil, S. J., J. K. Stoops, and V. C. Joshi. Fatty acid synthesis and its regulation. Annu. Rev. Biochem. 52: 537-579, 1983.
[0196] 37. Zhang, W., B. J. Wagner, K. Ehrenman, A. W. Schaefer, C. T. DeMaria, D. Crater, K. DeHaven, L. Long, and G. Brewer. Purification, characterization, and cDNA cloning of an AU-rich element RNA-binding protein, AUF1. Mol. Cell. Biol. 13: 7652-7665, 1993.
[0197] 38. Zubiaga, A. M., J. G. Belasco, and M. E. Greenberg. The nonamer UUAUUUAUU is the key AU-rich sequence motif that mediates mRNA degradation. Mol. Cell. Biol. 15: 2219-2230, 1995.
1
7
1
37
DNA
Artificial Sequence
/note=“synthetic construct”
1
gggggtgggg tggggtgggg tggggatggt ggagtga 37
2
47
DNA
Artificial Sequence
/note=“synthetic construct”
2
gatctagctt cccgctgatg agtccgtgag gacgaaacat gccggca 47
3
47
DNA
Artificial Sequence
/note=“synthetic construct”
3
gatctgccgg catgtttcgt cctcacggac tcatcagcgg gaagcta 47
4
37
RNA
Artificial Sequence
/note=“synthetic construct”
4
ucacuccacc auccccaccc caccccaccc caccccc 37
5
9
RNA
Artificial Sequence
/note=“synthetic construct”
5
uuauuuauu 9
6
10
DNA
Artificial Sequence
/note=“synthetic construct”
6
ccaccccacc 10
7
126
DNA
Artificial Sequence
/note=“synthetic construct”
7
cgcgugagcg ugcgggaggg cuaggcccgu gcccccgccu gccaccggag gucacuccac 60
cauccccacc ccaccccacc ccacccccgc caugcaacgg gauugaaggg uccugccggu 120
gggacc 126 | Disclosed is a 178 kDa glucose-inducible human fatty acid synthase (FAS) mRNA binding protein which has been purified to homogeneity and its binding element characterized. This large phosphoprotein binds to a novel repetitive element in the 3′ untranslated region (UTR) of the FAS mRNA. In particular, the binding has been mapped to a 37 nucleotide stretch within the first 65 bases of the 3′ UTR of mRNA. The binding protein is useful for mediating FAS expression, for regulating lipoprotein secretion and cell growth and for screening of test compounds for activity as inhibitors of FAS. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application relates to and claims the benefit and priority to European Patent Application No. EP13382502, filed Dec. 11, 2013.
TECHNICAL FIELD
[0002] The present invention is related to a doctor for a paper machine.
BACKGROUND
[0003] Some tools or elements in some machines are exposed to wear and must be periodically replaced. This is the case of paper machines used for manufacturing paper where a doctor with at least one blade that wears with use and must be periodically replaced is used.
[0004] Such machines have at least one roller from which the paper is generated, and the doctor can have different uses such as for cleaning the surface of the rollers or peeling the sheet of paper from the surface on which it adheres, for example. As mentioned, the doctor comprises at least one blade which acts on the roller by contact and which suffers wear, and further comprises a blade holder which supports the blade and allows assembling and removing same.
[0005] A way for detecting the wear of the blade before it becomes pernicious is by means of actual user experience, or even visually. These are not the most advisable techniques because the detection of the wear before it becomes pernicious is not assured in all cases (due to user oversight, for example) and also because it is not a comfortable and fast way for detecting same.
[0006] Other methods are also known where the wear of the blade is manually measured by means of devices that are suitable for such purpose in order to detect whether or not it is acceptable. For this purpose, the machine must be stopped periodically (periods which can depend on user experience or on previously established time, for example), accessing the blade with the relevant device and taking the measurement (there are cases in which it may even be necessary to completely or partially remove the blade from the doctor to take the measurement).
[0007] Document EP 1310592 A2 discloses measurement means for measuring the wear of the blade. The measurement can be taken contacting or without contacting the blade and in both cases a relative movement is required between the measurement means and the blade which allows measuring the wear of a blade when the blade is being changed, for example.
[0008] Document EP 1244850 A1 discloses a doctor in which the wear of the blade can be detected or measured during the operation thereof. The doctor comprises a blade, a support or blade holder which holds the blade and a main support which in turn holds the support, the support being able to rotate with respect to the main support. In one embodiment, the doctor comprises a sensor in the blade holder or in the main support for detecting the rotation or the movement between them, the wear of the blade being estimated depending on this detection. In another embodiment, the doctor comprises a plurality of optical fibers arranged in parallel in the blade, whereby light is passed there through such that, if a fiber is broken due to the wear of the blade, light no longer goes through the fiber and this event is detected, the wear thus being detected.
SUMMARY OF THE DISCLOSURE
[0009] A doctor for use in a paper machine and comprises at least one blade for scraping the surface of a paper roller and detection means which is associated with the blade and which, like the blade, is exposed to wear due to the contact with the roller. The detection means comprises a wearing element which is arranged in the blade and which is exposed to wear and a reading element associated with the wearing element.
[0010] The reading element excites the wearing element with a magnetic signal and the wearing element responds with a magnetic response signal which is received by the reading element, the magnetic response signal comprising a specific frequency varying with the wear of the wearing element, such that the frequency of the magnetic response signal is representative of the wear of the wearing element and therefore of the blade. Therefore, by means of detecting the frequency the wear of the blade (even the level of wear of the blade) or the absence of a useful blade when the wear reaches a predetermined level can be detected easily and without having to stop the paper manufacturing machine, for example.
[0011] These and other advantages and features will become evident in view of the drawings and the detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a partial perspective view of a doctor according to one implementation.
[0013] FIG. 2 is a partial plan view of the doctor of FIG. 1 without a support plate.
[0014] FIG. 3 is a partial bottom view of the doctor of FIG. 1 .
[0015] FIG. 4 is a schematic plan view of a wearing element according to one implementation.
[0016] FIG. 5 is a schematic plan view of a wearing element according to another implementation.
[0017] FIG. 6 is a schematic plan view of a wearing element according to another implementation.
[0018] FIG. 7 is a plan view of a reading element according to one implementation.
DETAILED DESCRIPTION
[0019] FIGS. 1 to 3 schematically show a doctor 1 according to some implementations that is suitable for being used in a paper machine. The doctor 1 is attached to a structure (not depicted in the drawings) of the machine and comprises a blade holder 11 , a blade 10 which is supported by the blade holder 11 , which acts on a roller (not depicted in the drawings) of the machine for scraping same and which wears with use due to the action, and can comprise a support plate 12 which is arranged connected to the blade 10 and which helps the blade 10 to act on the roller. It is also be possible that the doctor 1 not comprise a support plate. The blade holder 11 holds the blade 10 at one end of the blade 10 , whereas the other end 10 a of the blade 10 (the leading end of the blade that acts on the roller of the paper machine) is designed for acting on the roller. It is also possible that the doctor 1 does not comprise a blade holder 11 for holding the blade 10 , the blade 10 being directly attached to structure 19 of the doctor 1 by means of conventional attachment means, for example.
[0020] The doctor 1 further comprises detection means which is associated with the blade 10 and which, like the blade 10 , is exposed to wear due to contact with the roller. The detection means comprises a wearing element 20 arranged in or on the blade 10 , and a reading element 21 associated with the wearing element 20 . The wearing element 20 is arranged in or on the blade 10 such that it contacts the roller and is exposed to wear, being worn to substantially the same extent as the blade 10 wears. The reading element 21 is suitable for transmitting a magnetic excitation signal to the wearing element 20 and for capturing a magnetic signal from the wearing element 20 as a response to the magnetic excitation signal. As the wearing element 20 wears, the magnetic response signal to be received by the reading element 21 varies such that by means of detecting/determining the variation the wear of the wearing element 20 , and therefore of the blade 10 , can be determined as will be discussed in more detail below.
[0021] According to some implementations the magnetic response signal comprises a specific frequency varying with the wear of the wearing element 20 , such that the frequency of the signal is representative of the wear (or of the level of wear) of the wearing element 20 , and therefore of the wear of the blade 10 . The arrangement of the wearing element 20 in the blade 10 with respect to the end 10 a of the blade 10 depends on the degree of wear to be measured, for example:
The wearing element 20 can be arranged such that it is flush with the end 10 a of the blade 10 , such that the wearing element 20 contacts the roller and starts to wear from the time in which the blade 10 wears. The change in the frequency of the magnetic response signal is therefore directly proportional to the wear of the blade 10 . The wearing element 20 can be arranged at a specific distance with respect to the end 10 a of the blade 10 , such that the wearing element 20 starts to wear once the blade 10 has worn up to a previously established point (the positioning of the wearing element 20 depends on the selection of the point). The change in the frequency of the magnetic response signal is therefore proportional to the wear of the blade 10 , although in order to determine the total wear of the blade 10 , the wear thereof until the wearing element 20 starts to wear (until the frequency of the magnetic response signal starts to change), which is known in advance (previously established point), must be taken into account.
[0024] According to some implementations the wearing element 20 comprises an inductive element L and a capacitive element C forming a resonant circuit with a specific resonance frequency, as schematically shown by way of example in FIGS. 4 to 6 , the resonance frequency being the frequency of the magnetic response signal. The resonance frequency is determined from the following equation:
[0000]
Fr
=
1
2
π
L
C
[0000] wherein:
[0025] Fr: Resonance frequency.
[0026] L: Inductance of the inductive element.
[0027] C: Capacitance of the capacitive element.
[0028] Therefore, the resonance frequency depends on the values of the inductive element L and of the capacitive element C, a specific resonance frequency is thus established when designing the resonant circuit. When the wearing element 20 wears, at least one of the elements L or C wears physically, changing the value thereof, such that the resonance frequency also changes as a result of the wear.
[0029] According to some implementations the purpose of the inductive element L is at least to achieve, together with the capacitive element C, the resonance of the resonant circuit at a certain resonance frequency, to capture the magnetic signal coming from the reading element 21 and to transmit a magnetic response signal to the reading element 21 as a response of the excitation received from the reading element 21 , the magnetic response signal comprising a specific resonance frequency which depends on the inductance value of the inductive element L and on the capacitance value of the capacitive element C. According to some implementations the inductive element L corresponds with a coil and the reading element 21 comprises another coil 21 a as that shown by way of example in FIG. 7 , such that a magnetic coupling is generated between both coils resulting in the excitation of the wearing element and the magnetic response signal of the inductive element L (of the wearing element 20 ). The coil of the inductive element L can be made in different manners, as schematically shown in the examples of FIGS. 4 to 6 .
[0030] By knowing the initial resonance frequency, knowing when the detection means starts to wear can be easily determined by monitoring when the resonance frequency of the resonant circuit of the detection means begins to change. To that end, the machine can comprise control means (not depicted in the drawings) suitable for interpreting the information received by the reading element 21 of the detection means. The control means is communicated with the reading element 21 , and can correspond with specific control means for performing this function (which may be located in the doctor 1 ) or with control means of the machine that are programmed or designed for furthermore performing this function (for example, the microprocessor, controller or equivalent central device of the machine which controls machine operations).
[0031] The coils both of the reading element 21 and of the wearing element 20 can be a printed circuit or the like, can correspond with commercial coils, with ferrite cores or with any other conventional element.
[0032] According to some implementations the reading element 21 further comprises an electronic unit (not depicted in the drawings) capable of generating a signal with a specific frequency (or with a frequency within a specific range) which is fed to the coil 21 a which is magnetically coupled with the inductive element L of the wearing element 20 . The electronic unit can correspond with a generator that generates a sinusoidal signal (or another type of frequency wave) or with an oscillator circuit, for example. The power supply for powering the electronic unit to generate the magnetic excitation signal can come from the general power supply of the machine, for example, and the electronic unit can be continuously powered throughout the operation of the machine.
[0033] According to some implementations the wearing element 20 comprises a substantially L-shape with a first section extending parallel to an end 10 a of the blade 10 and a second section transverse to the first section, the capacitive element C being arranged in the second section and the inductive element L being arranged in the first section. According to some implementations the inductive element L is arranged at the end of the first section furthest from the second section. The wearing element 20 comprises a base 24 in which (or on which) the capacitive element C, the inductive element L and an attachment area 25 between both elements C and L are arranged, the area conferring the wearing element 20 with the substantially L-shape. The attachment area 25 corresponds with the physical attachment between the capacitive element C and the inductive element L.
[0034] According to some implementations the capacitive element C of the wearing element 20 is exposed to wear, such that the resonance frequency of the resonant circuit changes (increases) due to the physical wear of the capacitive element C (reduced capacitance value). Therefore, the second section of the wearing element 20 is closer to the end 10 a of the blade 10 than the first section. In addition to achieving, together with the inductive element L, the resonance of the resonant circuit at a certain resonance frequency, the purpose of the capacitive element C is to therefore act as a sensor element itself. The capacitive element C is subjected to the wear of the blade 10 of the doctor 1 , which would cause a reduction in the capacitance thereof and therefore an increase in the resonance frequency of the resonant circuit which it forms together with the inductive element L.
[0035] According to some implementations the blade 10 comprises a flange 10 c at one end on which there is arranged the end of the first section of the base 20 of the wearing element 20 where the inductive element L is arranged. The flange 10 c preferably prolongs parallel to the end 10 a as shown in FIGS. 2 and 3 . The doctor 1 comprises a support 4 which is attached to the blade holder 11 (or which forms part of the blade holder 11 , corresponding with an extension of the blade holder 11 ) and which is facing the flange 10 c of the blade 10 , where the reading element 21 of the detection means is arranged, such that the reading element 21 is facing the flange 10 c and therefore the inductive element L of the wearing element 20 , which allows the magnetic coupling between the wearing element 20 and the reading element 21 . It is also possible to achieve the coupling in other ways, such as facing the wearing element 20 and the reading element 21 to one another in the horizontal plane instead of in the vertical plane, or even without facing them to one another (having them within one and the same area of influence is sufficient, depending on the magnetic signal emission/reception strength).
[0036] According to some implementations the capacitive element C of the resonant circuit corresponds with a planar capacitor 22 such as that shown by way of example in FIG. 4 , formed by two metal plates arranged in parallel (only one plate is shown in FIG. 4 ), which can be copper plates (due to their high conductivity), for example, separated by insulation means such as air or glass fiber, for example. Each metal plate is attached to one end of the induction element L by means of a copper conductive wire 29 , for example. When the capacitive element C wears, the area of the two metal plates forming the planar capacitor 22 decreases, the capacitance of the capacitive element C being reduced and the resonance frequency of the resonant circuit which it forms together with the inductive element L being increased.
[0037] According to some implementations the wearing element 20 corresponds with a label adhered on the blade 10 (although it could also be arranged on the blade by attaching it to the blade 10 by means of another type of attachments or fastenings), such that the assembly thereof is very simple and quick.
[0038] According to some implementations the capacitive element C of the wearing element 20 comprises a planar capacitor 22 with a non-rectangular shape. For example, the planar capacitor 22 may comprise a maximum width at its end 22 a closest to the end 10 a of the blade 10 , which corresponds with the end thereof that is exposed most to wear, the width being reduced as it becomes further away from the end 22 a, as shown in FIG. 5 . The width is reduced to facilitate or simplify the determination of the wear of the wearing element 20 and therefore of the blade 10 , and has the purpose of providing a linear or substantially linear change in the resonance frequency as the wear of the wearing element 20 increases. With a linear change the level of wear of the blade 10 can be determined or calculated in a simpler manner. Therefore, the width is not reduced in a linear manner, but rather a non-linear (or non-uniform) manner whereby the linear change in the resonant frequency is achieved, such as the shape of the planar capacitor 22 depicted in FIG. 5 . FIG. 5 shows a single plate of the capacitor and a single conductive wire 29 , but each plate will be communicated with a corresponding end of the inductive element L with the corresponding conductive wire thereof.
[0039] According to some implementations the capacitive element C of the wearing element 20 does not correspond with a planar capacitor. In this case, the capacitive element C corresponds with an interdigitated capacitance 23 formed by conductive strips, such as that shown by way of example in FIG. 6 . When the wearing element 20 wears, the wear occurs on the conductive strips that will be gradually removed as the wear progresses, the capacitance value of the capacitive element C formed by the interdigitated capacitance 23 being reduced and the resonance frequency of the resonant circuit of the wearing element 20 thus being increased. The conductive strips are manufactured with a metal material such as copper. | A doctor for a paper machine that according to some implementations includes a blade, a wearing element located in or on the blade so that at least a portion of the wearing element is exposed to wear as the blade is worn, and a reading element positioned in proximity to the wearing element. The reading element is configured to emit a magnetic signal to excite the wearing element and the wearing element is configured to respond to the magnetic signal with a magnetic response signal. The reading element is in turn configured to receive the magnetic response signal, the magnetic response signal comprising a frequency that varies with the wear of the wearing element such that the frequency of the magnetic response signal is representative of the wear of the wearing element. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 12/280,629, filed on Aug. 25, 2008, which is a U.S. National Phase of International Application No. PCT/CU2007/000010, filed Feb. 28, 2007, which claims priority from Cuban Application No. CU 2006-0049, filed Feb. 28, 2006, all of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention is related to the field of molecular and experimental oncology, in particular to the description of a pharmaceutical combination directed to the treatment and/or chemosensibilization of refractory tumors to convencional cytostatics.
PRIOR ART
[0003] In the last three decades, the use of chemical drugs as cytostatics for cancer therapy constitutes one of the choices as first-line treatment for some solid and hematopoietic tumors. The most commonly used chemical drugs for cancer therapy are: cisplatin, taxols, alcaloids from Vinca, doxorubicin, 5-fluorouracil, cyclophosphamide among others (Jackman A. L., Kaye S., Workman P. (2004) The combination of cytotoxic and molecularly targeted therapies—can it be done? Drug Discovery Today 1:445-454). However, results from clinical trials exhibit a low therapeutic index for this kind of drug in cancer therapy as evidenced by the marginal therapeutic benefit along with the high toxicity profile observed in the patients (Schrader C., et al. M. (2005) Symptoms and signs of an acute myocardial ischemia caused by chemotherapy with paclitaxel (taxol) in a patient with metastatic ovarian carcinoma. Eur J Med Res 10:498-501). For example, many authors agree that cisplatin constitutes the first-line treatment for lung cancer, however a modest efficacy is commonly observed with little improvement on the clinical symptoms and 6-weeks increase of survival (Grillo R., Oxman A., Julian J. (1993) Chemotherapy for advanced non-small cell lung cancer. J Clin Oncol 11:1866-1871; Bouquet P. J., Chauvin F., et al (1993) Polychemotherapy in advanced non-small cell lung cancer: a meta-analysis. Lancet 342:19-21). Therefore, the current strategies to achieve an optimal therapeutic benefit are focused to pharmaceutical combinations based on conventional cytostatic drugs along with molecular targeted therapies. Some of the current anticancer drugs are classified as cancer targeted therapy, for instance, Gleevec (Imatinib) which targets the Abl kinase that in turns play an essential role on the development of Chronic Myeloid Leukemia (Giles J. F., Cortes J. E., Kantarjian H. M. (2005) Targeting the Kinase Activity of the BCR-ABL Fusion Protein in Patients with Chronic Myeloid Leukemia. Current Mol Med 5:615-623), also Iressa that targets tyrosine kinase associated to the Epidermal Growth Factor (EGF) receptor (Onn A., Herbst R. S. (2005) Molecular targeted therapy for lung cancer. Lancet 366:1507-1508) and Velcade (Bortezomib) which blocks the protein degradation by targeting the proteasome machinery (Spano J. P., et al. (2005) Proteasome inhibition: a new approach for the treatment of malignancies. Bull Cancer 92:E61-66), among others. Considering that the non-specific mechanisms of the conventional chemotherapeutics converge on the abrogation of cellular mitosis, the use of the new cancer targeted therapeutics provides great perspectives to achieve pharmaceutical combinations which produce synergism of the antitumor effect.
[0004] On the other hand, drug resistance phenomenon is recognized as the primary cause of the failure on cancer therapy when chemotherapeutic agents are employed. In spite of that sub-optimal drug concentration on the tumor milieu could influence the drug resistance, other factors like cellular origin plays an essential role on the chemo resistance for many tumors. Drug resistance is a multifactorial phenomenon depending on multiple independent mechanisms which involve intracellular detoxification, changes on the cellular response, tolerance to stress and defects on the apoptosis signaling pathways (Luqmani A. (2005) Mechanisms of drug resistance in cancer chemotherapy. Med Princ. Pract 14:35-48). The Glycoprotein-P and the Gluthathion S-transferase are the major proteins that mediate the intracellular detoxification process linked to the drug resistance phenomenon in cancer (Saeki T., Tsuruo T., Sato W., Nishikawsa K. (2005) Drug resistance in chemotherapy for breast cancer. Cancer Chemother Pharmacol 56:84-89) (Nara T., et al. (2004) Gluthathione S-transferase P1 has protective effects on cell viability against camptothecin. Cancer Letters 203:199-207). Other proteins like beta-tubulins have been reported to be involved on the drug resistance phenomenon and whose levels directly correlate with the tumor resistance to Paclitaxel (Orr G. A., et al. (2003) Mechanisms of Taxol resistance related to microtubules. Oncogene 22:7280-7295). Otherwise, the cisplatin resistance has been reported to be influenced by the over expression of different proteins like T-plastin (Hisano T., et al. (1996) Increased expression of T-plastin gene in cisplatin-resistant human cancer cells: identification by mRNA differential display. FEBS Letters 397:101-107), the Heat Shock Protein (HSP70) and (HSP90) (Jaattela M. (1999) Escaping cell death: survival proteins in cancer. Exp Cell Res 248:30-43) and the transcription factor YB1 (Fujita T., et al. (2005) Increased nuclear localization of transcription factor Y-box binding protein accompanied by up-regulation of P-glycoprotein in breast cancer pretreated with paclitaxel. Clin Cancer Res 11:8837-8844). Additionally, exacerbation of Glycolisis and Piruvate pathways has been reported to play an essential role on the chemo resistance phenomenon observed in tumor cells (Boros L. G., et al. (2004) Use of metabolic pathway flux information in targeted cancer drug design. Drug Disc. Today 1:435-443).
[0005] Reports from different groups have indicated the existence of a set of proteins which either inhibit apoptosis or increase cell survival on tumor cells thus contributing to the chemoresistance phenomenon of tumors. One of the examples is the Nucleophosmin protein which plays a central role on cell cycle promoting, inhibition of apoptosis and it has been regarded as a poor prognosis marker in cancer (Ye K. (2005) Nucleophosmin/B23, a multifunctional protein that can regulate apoptosis. Cancer Biol Ther 4:918-923). Likewise, the CK2 enzyme plays an important role on cell survival and in the resistance of tumor cells toward apoptosis (Tawfic S., Yu S., Wang H., Faust R., Davis A., Ahmed K. (2001) Protein kinase CK2 signal in neoplasia. Histol. Histopathol. 16:573-582). Previous findings have revealed the elevation of CK2 activity from 3- to 7-fold in epithelial solid tumors respect to the normal tissues (Tawfic S., Yu S., et al. (2001) Protein kinase CK2 signal in neoplasia. Histol Histopatol. 16:573-582; Faust R. A., Gapany M., et al (1996) Elevated protein kinase CK2 activity in chromatin of head and neck tumors: association with malignant transformation. Cancer Letters 101:31-35). Furthermore, the CK2 activity is an important cellular event for the malignant transformation and it constitutes a tumor progression marker (Seldin D. C., Leder P. (1995) Casein Kinase IIα transgene-induced murine lymphoma: relation to theileroiosis in cattle. Science 267:894-897). The fact that the CK2 phosphorylation represents a strong signal to protect tumor cells from apoptosis, it leads to the consideration of this enzyme as an antiapoptotic mediator on cellular physiology (Ahmed K., Gerber D. A., Cochet C. (2002) Joining the cell survival squad: an emerging role for protein kinase CK2 . Trends Cell Biol, 12:226-229; Torres J., Rodriguez J., et al (2003) Phosphorylation-regulated cleavage of the tumor suppressor PTEN by caspase-3: implications for the control of protein stability and PTEN-protein interactions. J Biol Chem, 278:30652-60).
[0006] Altogether, the CK2 phosphorylation is a biochemical event that represents a potential target for cancer therapy and specific inhibitors of this event could lead to drug candidates with perspectives cancer management.
[0007] Different groups have developed different strategies to inhibit the CK2 phosphorylation using two independent approaches: a) Direct inhibition of the CK2 alpha catalytic subunit, b) Direct targeting of the acidic domain on the CK2 substrates (patent WO 03/054002 and Perea S. E., et al. (2004) Antitumor effect of a novel proapoptotic peptide impairing the phosphorylation by the protein kinase CK2 . Cancer Res. 64:7127-7129). Using both approaches, authors have demonstrated the proof-of-principle that the CK2 inhibition lead to apoptosis on tumor cells. These findings reinforce the experimental validation of CK2 as a suitable target to develop anticancer drugs.
[0008] The comparative proteomic studies along with the development of molecular biology have permit in part, the understanding of the molecular mechanisms involved both in cell malignant transformation and tumor chemoresistance. Therefore, cancer therapy regimens should focus their attention in achieving effective drug combinations which greatly reduce toxicity and also reduce the possibility of chemoresistance arising.
[0009] Thus, one of the major goals today in cancer therapy is to increase the therapeutic index of the current cytostatic drugs by reducing the effective dose and the intrinsic toxicity displayed by this kind of medicines. Other current strategy is to bypass the tumor chemoresistance toward the conventional cytostatic drugs.
DETAILED DESCRIPTION OF THE INVENTION
[0010] This invention solves the problem above mentioned as it provides a pharmaceutical combination that contains two ingredients: a CK2 phosphorylation inhibitor (P15 peptide) and a cytostatic drug pharmaceutically acceptable.
[0011] In this invention, “cytostatic drug pharmaceutically acceptable” referrers to all the cytostatic chemical compounds used for cancer chemotherapy both for solid tumors and those from hematopoietic origin. The preferred cytostatics are cisplatin and carboplatin, paclitaxel and docetaxel, vincristin and vinblastin, 5-fluorouracil, doxorubicin, cyclophosphamide, etoposide, mitomycin C, imatinib, iressa, and velcade (Bortezomib), cytarabine (Ara C), fludarabine, and mitoxantrone, mixed with appropriated vehicles.
[0012] In this invention, the concept of “inhibition of CK2 phosphorylation” also includes any chemical or peptidic compound that blocks either the substrate or the enzyme itself. Depending on the situation, the active ingredients of this pharmaceutical combination can be administered simultaneously, separated or sequentially. The administration of this pharmaceutical combination can be performed by systemic, topic or oral routes. This invention also referrers to the treatment and/or the bypassing of the chemoresistance in refractory tumors occurring in human beings using the pharmaceutical combination mentioned above.
[0013] Likewise, this invention referrers to the use of the ingredients of this pharmaceutical combination to prepare a medicine to treat chemorefractory tumors and to increase the antitumor effect of the cytostatic drugs cited in this invention.
[0014] The example 1 (Table 1) shows that the pharmaceutical combinations described in this invention produce a synergistic antineoplastic effect in vitro. Thus, the simultaneous combination of sub-optimal doses from the P15 peptide along with cisplatin, paclitaxel, doxorubicin, vincristin, etoposide, mitomycin C, 5-fluorouracil, imatinib, or iressa, achieves a 10- or 100-fold reduction of the effective dose for each cytostatic drug mentioned in this invention. Effective dose is that achieves a 50% of the antineoplastic effect which is also termed Inhibitory Concentration 50% (IC50) in proliferation assays in vitro. In this invention, “sub-optimal doses” referrers to those lower than the IC50.
[0015] The example 2 illustrates the potentiation of the antitumor effect in vivo by using this pharmaceutical combination containing the P15 peptide along with cisplatin ( FIG. 1A ), cyclophosphamide ( FIG. 1B ) and mitomycin C ( FIG. 1C ). The pharmaceutical combination leads to the complete tumor regression in a relevant animal model like that consisting in a human tumor xenografted in nude mice. However, the use of the ingredients of this pharmaceutical combination like monotherapy did produce only a marginal delay on tumor growth compared to the effect observed in placebo group.
[0016] The sequential administration of the ingredients from this pharmaceutical combination demonstrates that P15 treatment bypasses the tumor chemoresistance both in vitro and in vivo. In this invention, it is understood that “bypassing of tumor chemoresistance or chemosensibilization” referrers to the event of reducing the drug dose needed to produce the 50% of the antitumor effect after pretreatment with the P15 peptide. The example 3 illustrates the effect of P15 peptide pretreatment in the chemosensibilization of tumor cells and it produces from 10- to 100-fold reduction of the effective drug dose. Similarly, data showed in table 3 represent that sequential administration of the pharmaceutical combination bypasses the intrinsic chemoresistance of tumors cells in vitro. In this invention, the in vitro chemoresistance is considered when the IC50 value reaches values upper than 1000 μM of concentration.
[0017] Similar to the in Vitro results, pretreatment with P15 peptide in vivo bypasses the tumor intrinsic chemoresistance (example 4) ( FIG. 2A , 2 B, 2 C).
[0018] The P15 peptide ingredient (amino acid sequence: CWMSPRHLGTC SEQ ID NO: 1) has been previously reported as a CK2 inhibitor (Perea S. E., et al. (2004) Antitumor effect of a novel proapoptotic peptide impairing the phosphorylation by the protein kinase CK2 . Cancer Res. 64:7127-7129). However, this peptide unexpectedly did regulate a group of proteins on tumor cells (Table 4) which reinforce and explain the synergistic antitumor effect of the ingredients among the pharmaceutical combination as well as the chemosensibilization produced by the pretreatment with the P15 peptide. For instance, the P15-regulated proteins play an essential role on the control of tumor cell proliferation and apoptosis and these mechanisms are not the same induced by the rest of the ingredients from this pharmaceutical combination, specifically the cytostatic preferred in this invention.
[0019] Likewise, other proteins that are regulated by the ingredient P15 are those involved in the molecular mechanisms of the tumor chemoresistance to the cytostatic preferred in this invention. These unexpected results constitute the molecular basis of the tumor's chemosensibilization produced by this pharmaceutical combination when the ingredients are sequentially administered.
[0020] A hallmark in this invention is the fact that effective concentrations of the cytostatic drugs in the pharmaceutical combination are 10- to 100-fold reduced compared to the effective dose when the cytostatic drugs are used alone. It means that a synergistic interaction occurs between the CK2 inhibitor and cytostatic drugs preferred in this invention. Since the practical point of view, this synergistic interaction means that the toxicity of the medicine based on this pharmaceutical combination is much lower than that observed for single cytostatic drugs.
[0021] Similarly, the tumor's chemosensibilization elicited after sequential administration of the ingredients from this pharmaceutical combination represents a great advantage as it permits to treat the chemoresistance which is frequently observed in solid tumors and in those ones from hematopoietic origin.
DESCRIPTION OF FIGURES
[0022] FIG. 1 : Potentiation of the antitumor effect by the pharmaceutical combination in a cancer animal model: (A) represents the synergism between cisplatin+P15, (B) represents the synergism between cyclophosphamide+P15, (C) represents the synergism in vivo of mitomycin C+P15.
[0023] FIG. 2 : Effect of tumor's chemosensibilization by the P15 peptide in vivo: (A) represents the bypassing of chemoresistance toward cisplatin, (B) represents the bypassing of chemoresistance toward paclitaxel and (C) represents the bypassing of chemoresistance toward doxorubicin.
[0024] FIG. 3 : Synergistic interaction between P15 peptide and anti-leukemic chemotherapeutics in vivo: A) P15+cytarabine (AraC), B) P15+Fludarabine, C) P15+Mitoxantrone.
[0025] FIG. 4 : Antitumor activity of P15+Carboplatin and P15+Etoposide in a cancer animal model: FIG. 4 is a graph demonstrating that P15 administered with etoposide or carboplatin elicits synergistic interactions in terms of antitumor effect in vivo.
DETAILED EXPOSITION OF THE EXAMPLES
General Procedures
[0026] Cell Cultures:
[0027] The H-125 cell line was arisen from a human Non-Small Cell Lung Carcinoma (NSCLC) and the SW948 cell line was arisen from a human colon carcinoma. The OCI-AML3 cell line was arisen from Acute Myeloid Leukemia (AML) type M4 (FAB). All the cell lines were maintained in RPMI 1640 (Gibco) culture medium supplemented with 10% Fetal Calf Serum and y gentamicin (50 μg/ml). Incubation of cell cultures was performed at 37° C. in 5% CO 2 .
[0028] Cell Viability Assay:
[0029] For this purpose, 20 μl of Tetrazolium (MTS) (Promega) were added to the cells on each plate. After 2 hours at 37° C., the absorbance at 492 nm was taken. Finally, the IC50 values were estimated from the respective dose-response curves using the “CurveExpert” software.
[0030] Cancer Animal Model:
[0031] The animal model used in this invention was based on the implantation of human tumors in nude mice (Nu/Nu, BalBC). Briefly, 5×10 6 H-125 or OCI-AML3 cells were suspended in Phosphate Buffer Solution (PBS) and inoculated subcutaneously. After tumor debut (approx. 30 mm 3 ), treatment was started using the pharmaceutical combination described in this invention. To evaluate the antitumor effect of the pharmaceutical combination, the tumor mass volume was measured and the respective volume was calculated using the formule: V=widght 2 ×lenght/2.
[0032] Analysis of the Protein Profile on the Cell Extracts:
[0033] H-125 cells were treated or not with the P15 peptide ingredient of the pharmaceutical combination described in this invention during 40 minutes. Subsequently, cell monolayers were washed with PBS and cells were scrapped from the surface. After two further washes with cold PBS, cellular pellets were resuspended in 10 mM tris-HCl pH 7.5, 0.25M sucrose, 1 mM EGTA+protease inhibitor cocktail and nuclear protein fraction was obtained as previously described (González L. J., et al (2003) Identification of nuclear proteins of small cell lung cancer cell line H82: An improved protocol for the analysis of silver stained proteins. Electrophoresis 24:237-252). To analyze the P15-regulated proteins, the respective nuclear protein extracts were alternatively solved by 2D bidimensional gels (pH 4-7) and/or Liquid chromatography (nano HPLC) coupled to Mass spectrometer.
[0034] This invention is explained by the following examples:
Example 1
Synergistic Effect of the Combination of P15 Peptide+Conventional Cytostatic Drugs
[0035] It was evaluated the antineoplastic synergistic effect between the P15 peptide ingredient combined with different cytostatic drugs in the following experimental conditions: H-125 or OCI-AML3 cells were seeded in 96-well plates and P15 peptide was added at 10 and 50 μM to each plate. Simultaneously, each of the cytostatic drugs preferred in this invention was added at doses ranging from 1 to 2000 nM and the incubation was prolonged during 72 hours in the same conditions. Finally, the cell viability and the IC50 values were determined as above described in this invention. Results showed in Table 1 demonstrate that the IC50 values for each cytostatic drug is 10- to 100-fold reduced when simultaneously combined with the ingredient P15 either at 10 or 50 μM. These results clearly demonstrate the potentiation of the antitumor effect of the pharmaceutical combination containing the P15 peptide and the cytostatic drugs preferred in this invention as ingredients.
[0000]
TABLE 1
Antineoplastic synergistic interaction by the simultaneous
administration of the ingredients in this pharmaceutical
combination.
Cytostatic
Cytostatic
Cytostatic
drug
drug +
drug +
Variant
alone
P15 (10 μM)
P15 (50 μM)
Cisplatin
720
nM
530
nM
40
nM
Paclitaxel
17
nM
8
nM
3
nM
5-Fluorouracil
1200
nM
420
nM
60
nM
Vincristin
856
nM
100
nM
8
nM
Doxorubicin
423
nM
200
nM
76
nM
Cyclophosphamide
2400
nM
1004
nM
85
nM
Mitomycin C
994
nM
93
nM
9
nM
Imatinib
600
nM
200
nM
58
nM
Velcade
2000
nM
1200
nM
700
nM
Iressa
689
nM
174
nM
47
nM
Etoposide
780
nM
60
nM
20
nM
Carboplatin
650
nM
70
nM
36
nM
Cytarabine (AraC)
1
mM
110
nM
68
nM
Fludarabine
870
nM
96
nM
50
nM
Mitoxantrone
754
nM
64
nM
32
nM
Example 2
Potentiation of the Antitumor Effect by the Pharmaceutical Combination in a Cancer Animal Model
[0036] For this purpose, 5×10 6 H-125 or OCI-AML3 tumor cells were implanted as above mentioned in this invention in 6-8 week-old BalBc nude mice. After tumor debut, the ingredients of the pharmaceutical combination were administered as follow: The P15 peptide in saline solution was administered intraperitoneal at 0.5 mg/kg/day during 5 days. Concomitantly, intraperitoneal injection of cisplatin ( FIG. 1A ), or cyclophosphamide ( FIG. 1B ) or Mitomycin ( FIG. 1C ) were performed at 1 mg/kg/day in the same frequency. The cytostatic drugs are also solved in saline solution. Tumor volume was registered as described above in this invention. The results showed in FIGS. 1A , 1 B and 1 C indicate that the pharmaceutical combination potentiate the antitumor effect when ingredients are simultaneously administered and as it was observed by the complete tumor regression. FIG. 3 shows data from combination of P15+anti-leukemic chemotherapeutics like cytarabine (Ara C), fludarabine and mitoxantrone, where a great synergistic interaction was observed in an animal model of AML. Otherwise, when ingredients are administered as monotherapy only a marginal antitumor effect was observed respect to the Placebo group. Thus, we further demonstrate the synergistic interaction between the ingredients among this pharmaceutical combination in an outstanding preclinical cancer model. Likewise, data from FIG. 4 show that P15 administered along with either etoposide or carboplatin elicits synergistic interactions in terms of antitumor effect in vivo.
Example 3
Effect of P15 Peptide in Bypassing the In Vitro Chemoresistance
[0037] In this assay we evaluated the effect of the pharmaceutical combination in bypassing the chemoresistance phenomenon when ingredients are sequentially administered. For this purpose, H-125 cells were seeded at 2000 cells/well in 96-well plates and after 24 hours 20 μM of the P15 peptide was added. After 16 hours of incubation with the P15 peptide ingredient, cell monolayers were washed twice with saline solution. Finally, the cytostatic drugs preferred in this invention were added at concentration ranging from 1 to 2000 nM and the incubation was prolonged during 72 hours. At the end, cell viability and the IC50 values for each cytostatic drug were determined as previously described in this invention. Results displayed in Table 2 demonstrate that pre-treatment of tumor cells with the P15 peptide ingredient increases the sensitivity of these cells to each of the cytostatic drugs preferred in this invention. Furthermore, we evaluated the effect of P15 pre-treatment on SW948 cells which are intrinsically resistant to the effect of the cytostatic drugs. Results demonstrated that the P15 peptide ingredient also converts to the intrinsic drug-refractory tumor cells into sensitive cells to the cytostatic drugs preferred in this invention. (Table 3).
[0038] Our data demonstrate that the sequential administration of the P15 peptide ingredient respect to the cytostatic drugs preferred in this invention leads to the sensibilization of tumor cells to the antineoplastic effect of such drugs.
[0000]
TABLE 2
In vitro chemosensibilization of the pharmaceutical combination
by sequential administration of the ingredients
Cytostatic drug
Cytostatic drug +
Variants
alone
P15 pre-treatment
Cisplatin
720
nM
20
nM
Paclitaxel
17
nM
0.9
nM
5-Fluorouracil
1200
nM
105
nM
Vincristin
856
nM
83
nM
Doxorubicin
423
nM
72
nM
Cyclophosphamide
2400
nM
100
nM
Mitomycin C
994
nM
20
nM
Imatinib
600
nM
10
nM
Velcade
2000
nM
370
nM
Iressa
689
nM
63
nM
Cytarabine (Ara C)
980
nM
340
nM
Mitoxantrone
700
nM
400
nM
Fludarabine
865
nM
300
nM
Carboplatin
450
nM
120
nM
Etoposide
561
nM
89
nM
[0000]
TABLE 3
In vitro chemosensibilization of the pharmaceutical combination
by sequential administration of the ingredients on intrinsic
drug-refractory tumor cells
Cytostatic drug +
Variants
Cytostatic drug alone
P15 pre-treatment
Cisplatin
≧1000 μM
120 μM
Paclitaxel
≧1000 μM
97 μM
Doxorubicin
≧1000 μM
320 μM
[0039] The effect of the P15 peptide ingredient on the chemosensibilization is further verified by the drug-regulated protein profile observed on the tumor cells used in this invention. For this purpose, nuclear protein extracts coming from H-125 cells treated or not with the P15 peptide ingredient were analyzed as previously described in this invention. Table 4 displays a group of proteins which are regulated by the P15 peptide ingredient and because of their known function; it reinforces the molecular basis for the tumor's chemosensibilization produced by this peptide in the pharmaceutical combination in this invention.
[0000]
TABLE 4
P15-regulated protein profile
Down-regulated proteins by
the P15 peptide ingredient
Inhibition rate
Nucleofosmin
48
T-Plastin
3.34
Heat Shock Proteins (HSP-27, -70 y -90)
2.5
Y-box1 transcription factor
3.33
Eritropoietin precursor
120
S-gluthathione transferase
4.87
Proteasome activator complex
3.35
Ubiquitin activated E1 enzyme
2.49
Glucose-6-phosphate isomerase
8.53
Gliceraldehyde 6-phosphate deshydrogenase
6.62
Piruvate kinase
8.34
Translational controled tumor protein
4.32
Up-regulated proteins by
the P15 peptide ingredient
Activation rate
Prohibitin
2.28
Tubulin alpha-1
3.23
Tubulin beta-2
2.56
Tubulin beta-3
3.15
Example 4
In Vivo Chemosensibilization Produced by the P15 Peptide Ingredient
[0040] For this purpose, 5×10 6 SW948 cells were implanted in nude mice as previously described in this invention. After tumor debut the pharmaceutical combination was sequentially administered as follow: First, the P15 peptide ingredient was administered intraperitoneal at 0.5 mg/kg/day during 5 days. Subsequently, cisplatin ( FIG. 2A ), Paclitaxel ( FIG. 2B ) and doxorubicin ( FIG. 2C ) were administered at 5 mg/kg/day during further 5 days. The results here demonstrate that the in vivo P15 pre-treatment is able to revert the chemorefractory phenotype of the tumors which become responsible to the cytostatic drugs preferred in this invention. These findings also provide the evidences that the pharmaceutical combination in this invention is able to bypass the commonly observed intrinsic tumor resistance when the ingredients are sequentially administered.
INCORPORATION OF SEQUENCE LISTING
[0041] Incorporated herein by reference in its entirety is the Sequence Listing for the application. The Sequence Listing is disclosed on a computer-readable ASCII text file titled, “sequence_listing.txt”, created on Oct. 20, 2014. The sequence_listing.txt file is 1 kb in size. | This invention is related to a pharmaceutical combination that contains a Casein kinase 2 (CK2) peptide inhibitor (termed P15) along with the standard chemotherapeutic drugs used in cancer treatment and which are administered together, separated or sequentially. The chemotherapeutic drugs include cisplatin, taxol, alkaloids from Vinca, 5-fluorouracil, doxorubicin, cyclophosphamide, etoposide, mitomycin C, imatinib, iressa, velcade (bortezomib), cytarabine (Ara C), fludarabine and mitroxantrone. The synergism between the P15 peptide and the anticancer drugs achieves an efficient concentration of each cytostatic drug in the combination which is from 10- to 100-fold lower than that for each cytostatic drug alone. The pharmaceutical combination described in this invention exhibits lower toxicity compared to that reported by the anticancer therapeutics and therefore, it represents a crucial advantage for its use in cancer therapy. Furthermore, the sequential administration of this pharmaceutical combination through the pretreatment with the P15 peptide leads to the chemo sensibilization of refractory tumors to the anticancer therapeutics. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a protectively encapsulated radio frequency identification device (RFID) and method of use. The invention further relates to an improved method for the sanitary processing of animals that utilizes the novel RFID. By incorporating the inventive RFID in the unique processing method disclosed herein, greater levels of safety and sanitation will be available while at the same time improving the palatability and consistency of the meat product.
2. Description of the Related Art
There exists a need in the meat packing industry for a method of tracking and identifying the various steps and procedures involved in preparing and processing an animal for human consumption. This need has arisen as a result of consumers and advocate groups' demands for cleaner facilities and safer meat handling methods. As a result many proponents have advocated for increased product sanitation by forcing processing plants to ensure that during each stage of the processing procedure the sanitary quality of the product remains uncompromised.
In an attempt to address this highly significant concern many meat processors have instituted tracking systems within their processing plants. These systems are intended to give the plant operators the ability to control all procedures which each animal is subjected to on an individual basis. Such specific tasking control will allow the operator the ability to ensure that each and every animal that enters the processing line is subjected to every sterilization and sanitation procedure without variance.
While these tracking systems are an essential addition to the meat processing industry, those systems which have been implemented have failed in a number of regards. Foremost of the problems that the various manufacturers of tracking systems have failed to take into account, is the extremely hostile environment of a meat processing plant. Two examples of such systems that have been applied to the industry are bar code based systems, and vision based systems. Bar codes were found to not be effective in the dirty and harsh environment of the abattoir, while vision systems offered only a high maintenance, obtrusive, and expensive alternative. As a result of these failings it is apparent that the need remains within the meat packing industry for a an improved, low cost, simple maintenance, and unobtrusive tracking system that is capable of operating within the hostile environment of a meat processing plant. To meet this continued tracking system need the presently disclosed invention proposes utilizing the disclosed RFID and associated novel processing method as an ideal solution.
SUMMARY OF THE INVENTION
The inventive system disclosed herein addresses the aforementioned problems in addition to many others. By employing a novel encapsulated radio frequency identification device into an improved animal processing system a resulting method for processing animals is created that increases safety and sanitation levels.
Radio frequency identification tags are known to be used in the food processing and other industries. The PROTECH Labeling Systems, PROTag™ Electronic Trolley Identification System is an example of using a radio identification tag to track shackles through a food smokehouse. The PROTag T system differs from the proposed system in that the PROTag™ system encloses a radio frequency identification tag into an elastomeric form which screws into a stainless steel or plastic mounting ring. Such mounting does offer some degree of physical protection to the tag from the outside environment, but the mounting ring may be damaged or break off making repair or replacement difficult.
The proposed RFID overcomes this prior application by completely enclosing the radio tag within a novel molded protective resin form. The resulting encapsulated RFID disclosed herein offers a greater amount of physical protection for the tag itself, and also prolongs the useful life of the tag. The proposed system is also easier to install, and maintain than present art. When employed as the tracking component of the system described, the RFID will allow the user to track every operation of the system which will help to insure uniform application of all sanitary procedures.
In addition to improving the degree of sanitation in the meat packing industry, the present invention addresses a second need as well. Recent surveys and studies by the National Cattleman's Beef Association (NCBA) and others have found that possibly as much as a third of the potential consumer market has stopped eating many meat products, especially beef, due to a perceived lack of palatability. As a result of such findings it is apparent that a need exists to develop a means of increasing beef palatability in order to regain this lost market share. Consequently, in addition to improving sanitary practices within processing plants, the novel processing method disclosed herein utilizes a system of sterilizing rinses and cooling injections to lower the pH levels within the animal carcass. This injection procedure has the benefit of giving the meat a more appealing and uniform color, texture, tenderness and taste. Furthermore, the disclosed treatment also increases shelf-life and retards premature spoilage.
The combination of benefits described above and further described herein, are the consequence of utilizing, in combination, the novel encapsulated radio frequency identification tag and the further novel use of the Meat Processing Service Corporation (MPSC) Rinse & Chill Technique (R&CT). The R&CT process uses a pH lowering and temperature reducing solution to rinse out residual blood through the R&CT process, bringing about a natural change in pH which bestows many benefits. There are also other benefits that are not related to pH reduction that the R&CT provides, such as easier removal of the hide. The encapsulated radio frequency identification tag and R&CT system combine to form a processing system with greatly improved sanitary and safety features while at the same time dramatically increasing the value of the end meat product.
In the inventive method for the sanitary rinsing of an animal, an assembly line is provided which includes a plurality of shackles. Each shackle includes an inventive RFID tag which includes a machine readable unique shackle number. Once an animal is stunned and attached to a shackle the animal is moved to a weighing station, which is equipped with an RFID tag reader, weighs the animal and transmits the weight and shackle number to a computer where the data is recorded in a database. The animal is then bled and moved to a rinsing station, which is equipped with an RFID tag reader which reads the shackle number. The system then looks up the weight of the animal to be rinsed at that particular rinsing station and calculates the amount of solution to inject into the circulatory system of the animal. After the end of the hose and nozzle and the operator's hands are sanitized, which is verified by the system, the nozzle is inserted into an entry point into the circulatory system and the operator starts the flow of the predetermined amount of solution into the animal. If the flow is not started within a time window, the operator must re-sanitize.
The inventive RFID tag is made by pouring curable liquid into a preformed mold to a first predetermined depth. A predetermined time is allowed to pass to permit the curable liquid to gel, but not sufficient to allow the liquid to fully cure. The circuitry is then placed upon the surface of the now gelled liquid and the mold is filled to a second predetermined depth with additional curable liquid. A second predetermined amount of time is allowed to pass to allow both the first and second depths of the poured curable liquid to fully cure and attain a homogeneous interface between the two depths, thereby preventing the occurrence of a seam between the two depths of now cured liquid.
This method produces an encapsulated RFID which keeps all metal objects at least 1/4, but preferably 1/2 inch away so that the metal objects do not interfere with the radio frequency communication. The encapsulating material is a polyurea elastomer compound.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
FIG. 1 is an overhead schematic of a preferred embodiment of the inventive processing method;
FIG. 2 is a second schematic representation of the preferred embodiment of the inventive processing apparatus;
FIG. 3 is a generalized block diagram illustrating the relative position and communicative interaction of the RFID reader system components;
FIG. 4 is a top view of the sanitization station;
FIG. 5 is a frontal view schematic representation of the encapsulation bracelet and encased tag;
FIG. 6 is a top-down view schematic representation of the encapsulation bracelet and encased tag;
FIG. 7 is a top-down view of the hose, nozzle and associated encapsulation bracelet;
FIG. 8 is side view of the engaged bath and nozzle assembly with associated encapsulation bracelet;
FIG. 9 shows a top schematic view of the sanitize station;
FIG. 10 shows a side view of the nozzle bath;
FIG. 11 shows a side perspective view of an operator at the sanitization station;
FIG. 12 is a frontal view schematic representation of the preferred embodiment RFID;
FIG. 13 is an overhead view schematic representation of the RFID, and
FIG. 14 is a side view schematic representation of the RFID.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description and the accompanying drawings are provided for purposes of describing and illustrating presently preferred embodiments or examples of specific embodiments of the of the invention only. This description and accompanying drawings are not intended to limit the scope of the invention in any way.
Referring to FIG. 1-3 of the accompanying drawings the animal processing system 10 is shown in a preferred assembly line format. FIG. 1 illustrates the various steps involved at each point of the animal processing system 10, and further illustrates where various components of the system are placed in relation to one another. FIG. 2 better illustrates the various components of the inventive process. FIG. 3 illustrates the communicative relationship between various electronic components of the animal processing system 10. While the present embodiment demonstrates the system as used with cows 14, the system also works for other animals such as cattle, sheep, or turkeys, in alternate embodiments.
This preferred embodiment is controlled by electronic processing units, such as computers. The computer used in this preferred embodiment is a programmable logic controller (PLC). The PLC is a minimally configured computer that is generally operated without a monitor, keyboard, floppy drive, hard drive, or mouse. Programming and service of a PLC generally takes place over a serial connection, such as RS232, to a separate program development computer, which is generally either a desktop or portable personal computer. The computer 54 incorporated within the preferred embodiment is intended to be an Allen-Bradley SLC500 Programmable Logic Controller.
A database is used to track information relating to the rinsing and chilling process. The database 55 may be stored entirely or partially on computer 54. This preferred embodiment stores only the RFID tag numbers and associated weights in database 55 on computer 54. When a rinse is initiated, this information, plus a time stamp and other process information is transferred to a second database 59 on a data acquisition computer 57. This transfer takes place over a serial communications link network between the computers. Database 59 may also store information from other components of the system, such as the mix station computer 52. The mix station computer 52 also provides information directly to the rinse station computer 54. This information from the mix station is used for system interlocks of the rinse station, allowing the rinse process to start only after the entire system has gone through a clean-in-place (CIP) and sanitize process, and viable rinsing solution is circulating throughout the system.
The process of stunning an animal for slaughter is well known within the art. This stunning results in the animal becoming irreversibly unconscious. In this embodiment, the cow 14 is stunned in stunning area 18. Upon being stunned the cow 14 is attached to a wheeled shackle 22 by one of the rear legs 26 of the cow 14. As indicated by the wheeled shackle 22 detail in FIG. 1, bolted to the wheeled shackle 22 is an encapsulated RFID 30, which encapsulates an electronic tag 58. The wheeled shackle 22 is then mounted to the overhead rail 34 to suspend the cow 14 from the overhead rail 34 in an inverted position. The overhead rail 34 is constructed in a manner to allow the wheel 38 of the wheeled shackle 22 to have essentially unrestricted bi-directional motion while mounted to the overhead rail 34, and this method of rail-shackle mounting is well known in the art.
An additional feature of the preferred embodiment, the animal processing system 10 can be a modification or addition to an existing processing system by redirecting and adding to existing overhead rail 42.
Once appropriately suspended the cow 14 is moved along the overhead rail 34 to a weight scale 46 and associated first RFID reader 50. At the weight scale the cow 14 is weighed. Once a stable weight reading is attained, the weight scale 46 sends the weight information to a computer 54, and stores this information in a database 55 on computer 54. The database takes the form of records in a table for storing the shackle number, the weight of the animal and optionally the time and date, as well as a processed indicator. Subsequently, the first RFID reader 50 accesses the information stored in the memory of the electronic radio tag 58 and likewise sends this information to the computer 54. As rinses are started for the animals, the information associated with that animal and shackle is moved to another computer 57 and database 59, thereby clearing the original database. If an animal is not rinsed and the RFID information is not moved, upon sensing the tag at RFID reader 50 again, the earlier entry of that RFID information is cleared and replaced with the new information. In the preferred embodiment, off-the-shelf wireless transmitters and receivers are used to communicate this information from the RFID tag readers to the computer 54. In an alternate embodiment, these RFID tags themselves may have weight information written directly to them and stored for retrieval at the time of rinsing. Upon obtaining the respective information from the weight scale 46 and the first RFID reader 50, the computer 54 will associate the individual number of each tag 58 and the corresponding weight of each cow 14 in the database. It should be understood, as is well known in the art, the components of the animal processing system 10 may be connected conductively, optically, or wirelessly. For example, the RFID tag readers may communicate wirelessly with the computer by transmitting the information with a transmitter and receiving the information at the computer with a receiver, as is well known in the art.
The aforementioned electronic components of the preferred embodiment disclosed above use the Escort Memory System (EMS), a DATALogic Group Company, line of radio frequency identification tags which are capable of storing a multiple-digit number within the electronic memory of the tag 58, specifically for the purpose of identifying the tag 58 during use. The presently preferred embodiment uses the EMS EH620HT RFID tag and the EMS RS400 RFID reader with the EMS AS15 antenna. Other RFID tags and readers by EMS and other manufacturers may also be used in this system. Similarly, the Escort Memory System tag reader is the model of tag reader utilized by the disclosed preferred embodiment in the form of the RFID readers. The Escort Memory System's tag reader is designed to sense and read a radio tag 58 signal when the distance between the tag and the tag reader is typically less than 3.4 inches. Throughout the inventive system disclosed herein it should be understood that the respective tag readers are positioned in such manner as to ensure an acceptable communicative distance from the relevant encapsulated radio frequency identification devices.
After the weight has been obtained and transmitted to computer 54, the cow 14 moves off of the weight scale 46 to a bleeding station 62 where the cow 14 is bled. The process of sticking and bleeding the animal is a procedure well known and described within the art. For this preferred embodiment, the cow 14 is to be bled through the jugular veins and the carotid artery. The cow 14 is then moved along the overhead rail 34 over a blood pit 66 toward the rinse start area 70.
Prior to entering the rinse start area 70 the cow 14 must pass through a first separation door 74. In alternate embodiments, these separation doors 74 are not used. Upon passing through the first separation door 74, the overhead rail 34 separates into multiple gravity-rails 78. In the embodiment illustrated herein, the animal processing system 10 utilizes three gravity-rails 78, however this embodiment is not intended to limit the number or type of rail 78 or manner of motivation which could otherwise be employed. The gravity-rails 78 guide the cow 14 from the overhead rail 34 to the rinse start area 70. In alternate embodiments, the rails used to convey the cow 14 may have moving members, such as chains, so as not to rely on gravity for motivation.
After the cow 14 has moved onto the divided rail 78, it passes through a first transparent door 96, thereby entering the rinse start area 70. In the preferred embodiment the first transparent door 96 and the second transparent door 100 are Jamison Auto-Clear transparent doors. These are automatically opened by a control switch activated by the operator. In alternate embodiments, these doors may be manually operated, or controlled by a switch on the rail activated by the presence of a shackle.
At the start of each rinse start area 70 a second RFID reader 82 is positioned. As the cow 14 passes the second RFID reader 82 the RFID 30 is again read. Upon sensing the tag 58, the second RFID reader 82 sends the individual tag 58 identification number to the computer 54.
Adjacent to the rinse start area 70 is a rinsing station 84. The rinsing station 84 includes a hose 88 and an attached nozzle assembly 92 with a further attached encapsulation bracelet embodiment of the RFID 108, all of which are illustrated with greater detail in figures. 5-8. In the preferred embodiment the nozzle assembly 92 further has an attached secured sanitary catheter 112 as disclosed in pending U.S. patent application for Secured Sanitary Catheter, Ser. No. 08/870,195, filed Jun. 6, 1997 to Meat Processing Services Corp., Inc., the entire contents of which are hereby incorporated by reference.
In the rinse start area 70 and adjacent to the rinsing station 84 is the sanitize station 104. The sanitizing station is shown best in FIG. 4, which is a top view of station 104, and will also be discussed in connection with FIGS. 5-8, which show top and side views of the RFID bracelet 108 (FIGS. 5-6) and top and side views of the nozzle assembly 92, RFID reader 136 and sanitizing bath 117 (FIGS. 7-8). FIG. 9 shows a top schematic view of the sanitize station 104. FIG. 10 shows a side view of the nozzle bath 117. FIG. 11 shows a side perspective view of an operator at sanitization station 104. The sanitizing of the hose, nozzle and operator's hands will discussed below with reference to FIGS. 4-11.
The sanitizing station 104 is used to sanitize the hose, nozzle, and the operator's hands before each use. Sensors and computer program interlocks between the rinse station 84 and the sanitize station 104 combine to require that certain activities are performed in a particular order before a rinse is allowed to start. Initially, the hose 88 and nozzle 92 are rinsed by water hose spray 115 and then dipped in the hose bath 116. In this embodiment, the water hose spray 115 may be directly connected to the sanitize station 104. In other embodiments, the water hose spray 115 may be remotely located. Water hose sprays are common to abattoir sites and are well know in the art. The hose bath 116 contains a solution of chlorinated water or similar cold sanitizing solution. Upon removal from this first solution the nozzle 92 is then inserted into one of the two nozzle sanitizing baths 117 or 118, which contains hot sterilizing (82° C. or hotter ) water. The two baths 117 and 118 allow two hoses to be sterilized to speed processing. Since the construction and operation of both baths 117 and 118 are identical, only bath 117 will be discussed below.
The nozzle 92 is equipped with a locating collar 120 (best seen in FIG. 8) which has a predetermined diameter constructed in a manner to rest over the bath opening 124. The nozzle 92 is held in position by a bracelet support frame 140. The bracelet support frame 140 is sized such that the RFID bracelet 108 fits and is held securely. The bracelet support frame 140 also positions the RFID Bracelet 108 to be read by the third RFID reader 136. The hose 88 may be further constrained by a hose hook 141 (best seen in FIG. 10) positioned above the bracelet support frame 140. Locating collar 120 rests in ridge 126 above overflow vent 132. Sanitary coupling nut 161 couples hose 88 to nozzle 92.
The third RFID reader 136 is attached to a bracelet support frame 140 which engages the encapsulation bracelet RFID 108 when the nozzle 92 is properly inserted and secured into the nozzle sanitizing bath 117. The support bracket 140 is mounted to the sanitize station 104 by a mounting shaft 144 which collectively functions to keep the hose 88 and nozzle assembly 92 properly positioned so that the incorporated third RFID reader 136 can stay in continuous reading contact with the encapsulation bracelet RFID 108 for the time interval which is required to properly sanitize the nozzle 92.
This time interval for sanitation is determined by the exact temperature of the sanitizing bath. Thermal probe 129 is used by computer 54 to monitor the temperature of the nozzle sanitizing bath. For a temperature of 82° C., the sanitary catheter 112 portion of the nozzle 92 will need to be submerged no less that 10 seconds. The required time in the sanitizing bath is inversely proportional to the temperature of the sanitizing solution.
When the third RFID reader 136 detects the encapsulation bracelet RFID 108 a signal is sent to the computer 54. Only after the signal has been detected for the required continuous time period by the computer 54, will the computer 54 signal the user via lamp 147 that the nozzle is ready to be used for a rinse. The signaling is done electronically via a user interface 143 and user interface panel 145, schematically shown in FIG. 9, which contains a plurality of status and alarm lamps. Nozzle bath #1 status lamp is shown at 147 and its alarm at 149. Nozzle bath #2 status lamp is shown at 151 and its alarm at 153. Bath #2 allows the operator to be sanitizing a second hose and nozzle while using the first. The hose bath status lamp is shown at 155 and the hand bath status lamp is shown at 157. If the signal between the encapsulation bracelet RFID 108 and the third RFID reader 136 is interrupted prior to the completion of the predetermined immersion time, the computer 54 will require the user to restart the nozzle sanitation process before allowing that nozzle to be used for a rinse. If the nozzle 92 is removed from the sanitizing nozzle bath 117, thereby removing the RFID bracelet 108 from the reading field of the RFID reader 136, before the appropriate sanitizing time has expired, or if the temperature of the nozzle sanitizing bath drops below a specified limit, or if the nozzle will not be sanitized within a specified time limit, the computer 54 will activate the audible alarm 149 and the associated nozzle bath alarm lamp, both located on the user interface panel of the sanitize station 104.
Before the computer 54 allows a properly sanitized nozzle to be used for a rinse, the hands of the operator must also be sanitized by a similar procedure. First, the user must rinse off their hands and arms. Second, the user must dip one hand into each of the hand bath reservoirs 148 and 154 of cold sanitizing solution of at least 20 PPM chlorinated water, these reservoirs 148 and 154 being located at the sanitize station 104. Within each hand bath 148 and 154, is a float switch. Float switch 150 is in hand bath 148, while float switch 152 is in hand bath 154. These two float switches, 150 and 152, must be engaged simultaneously in order to proceed. To ensure that this step is followed the float switches 150 and 152, once engaged, signal the computer 54 that the step has been completed. When the float switches 150 and 152 are engaged properly, the computer 54 activates the hand bath status lamp 157 indicating to the operator that the nozzle pull timer has started. Once the nozzle pull timer is started, the operator has a limited amount of time to pull a properly sanitized nozzle for use. If the nozzle pull timer expires before the operator has pulled the nozzle, the hand bath status lamp 157 is deactivated. If the operator pulls a sanitized nozzle when the hand bath status lamp 157 is deactivated, the computer 54 will reset all of the sanitize flags and not allow that nozzle to be used for rinsing until the sanitize process is done properly.
After properly sanitizing both of their hands and arms, the operator is ready to locate the artery of the cow 14, in which to place the nozzle 92 for the rinse. Once located the operator pulls the nozzle 92 from the nozzle sanitizing bath 117, making sure the nozzle valve 160 (best seen in FIG. 4) is closed. This action causes the RFID bracelet 108 to leave the sensing field of RFID reader 136. The RFID reader signals the computer 54 that the nozzle 92 has been removed. The computer 54 checks the status of the nozzle and hand sanitation processes through bit flags set in its memory. If the nozzle 92 and operator hands have been properly sanitized, the computer 54 then checks RFID reader 82 for a valid shackle RFID 30. If a valid shackle RFID 30 is present, the computer 54 searches its database 55 to find the weight associated with that RFID 30. With this weight information, the computer 54 determines the proper amount of rinsing solution to use for that given cow 14. The computer 54 then actuates valves in the rinse station 84 allowing fluid to fill the hose 88 and nozzle 92. The computer 54 then turns off the hand bath status light 157 and the nozzle bath status light 147 (assuming bath #1 used) of the bath from which the nozzle 92 was drawn, and resets all of the sanitize sequence bit flags for the nozzle and hand bath. Resetting these bit flags prepares the sanitize station 104 for the next sanitizing sequence. The computer 54 then activates the hose status light 159 associated with the selected hose, and starts to monitor the flow through the hose by use of a flow meter in the rinse station 84.
Once the hose 88 and nozzle 92 are enabled with injectable rinsing and cooling solution, the operator must insert the nozzle 92 (in the preferred embodiment the aforementioned secured sanitary catheter 112 which is attached to the nozzle 92 is inserted) into the carotid artery of the cow 14 before a preset time has elapsed. If the preset time elapses before the computer 54 detects flow through the flow meters of rinse station 84, the audible alarm is activated and the associated hose lamp 159 is deactivated. Upon proper insertion, the operator manually opens a valve 160 to begin the flow of injectable solution into the circulatory system of the cow 14.
Once the rinse is properly started in the cow 14, the operator activates a switch opening transparent doors 100 allowing the rinsing animal to move along down the rail. In alternate embodiments, the cows 14 will be continuously conveyed along the rail through out the rinse start area 70 and into the remaining rinse area, and the doors 100 will be opened automatically.
As the cow 14 is being rinsed, the computer 54 monitors the flow of rinsing solution through the flow meters in rinsing station 84. The prescribed volume of the rinsing solution is allowed to flow through the circulatory system of the cow 14 and drain out the jugular veins of the cow 14. Once the prescribed volume of rinsing solution has been administered, the computer 54 closes the valve in the rinsing station 84 which was supplying rinsing solution to that hose 88. The computer 54 also deactivates the hose status light 159 associated with the given hose 88. The operator then washes their hands and removes the nozzle 92 from the cow 14. The operator begins the sanitizing process over again by using the spray hose 115 to clean their hands, arms, nozzle 92, and hose 88. The preferred embodiment uses four (4) hoses so that up to four (4) cows 14 may be rinsing at any given time. Each hose is then available and used again for every fourth cow 14.
FIG. 12-14 details the various components that make up the RFID of the disclosed preferred embodiment. The manner of encompassing the electronic radio tag 58 ensures that the tag 58 is always kept insulated from ferrous material which is known to interfere with the operation of the tag 58 when in close proximity. The front of the tag is to have no metal at all between it and the RFID antenna. More space allows for more reading range. The shackle RFID enclosure is configured for at least 1/2" on back, 5/8" to a washer, and 1/2" to the support bolts. Exact read range is determined by tag size, RFID reader power and amount of and area covered by the ferrous material. Which materials interfere with magnetic and radio waves are well known to those in the field of RF identification and other fields. Steel is an example of such a material that limits RFID read range. Furthermore, such an enclosed tag 58 is protected from a wide variety of hostile environmental conditions such as high heat, high humidity, and high shock or impact. In the disclosed preferred embodiment the molded protective casing 164 is made from a curable liquid polyurea elastomer, sold under the trade name REN:C:O-THANE® by Ciba-Geigy Corporation, Formulated Systems Group.
The method of manufacture for the preferred embodiment involves pouring a predetermined amount of the curable liquid polyurea elastomer into a performed mold sufficient to fill the mold to a depth of at least 1/8 of an inch. This initial amount of polyurea elastomer is allowed to gel. Once the polyurea elastomer has gelled the electronic radio tag 58 is placed upon the gel in the desired position. After the tag 58 is placed the remaining amount of liquid curable polyurea elastomer is poured into the mold. In order to ensure a seamless fusion between the fist gelled layer of polyurea elastomer and the second, it is essential to the process to pour the second amount before the first layer is allowed to fully cure. In order to ensure proper insulation from ferrous material the distance separating the tag and the top of the mold must be at least 1/4" of an inch, however 1/2" is preferred.
Subsequent to fully curing, the polyurea elastomer resin casing 164 is modified in a manner to allow the RFID to be mounted to a variety of surfaces. Drilled in a uniformly spaced manner are two insertion holes 168 which extend through the entire mold. These holes are drilled through at indentations in the resin made as a result of the mold design. The mold also includes contours that create holes of increased diameter spaces 172 suitable for placement of a bolt head, nut or other enlarged securing device on the same centers as the bolt insertion holes 168. It would be possible to avoid the added expense and effort of drilling the aforementioned components in an alternative embodiment by placing pre-existing members or appropriate dimensional character in the original mold form. In the preferred embodiment the bottom surface corners and sides 176 of the polyurea elastomer resin casing are rounded by the shape of the mold as is well known in the art. Further operations to the resin casting may include sanding and cutting to trim excess material and to smooth some surfaces. These sanding and cutting operations are well known in the art. The features of having a seamless fusion of the two portions of the casing, as well as having rounded corners and sides 176, help to make the RFID more resistant to physical impact, shock, and breakage.
FIGURES. 5-6 illustrate an alternative encapsulation bracelet embodiment of the RFID 108 device in which an annular opening 180 is drilled or provided for, which allows the encapsulation bracelet RFID 108 to be mounted directly onto the hose 88 as shown in FIG. 7-8. In an alternate embodiment, the encapsulation bracelet may be mounted on a mounting protrusion made part of the nozzle assembly 92. The nozzle assembly 92 is inserted into the nozzle sanitizing bath 117 in a manner that ensures the portion of the bracelet containing the electronic radio tag 58 is facing the third RFID reader 136 when the encapsulation bracelet RFID 108 is engaged with the support bracket 140. This positioning is accomplished by the operator through visual inspection of the encapsulation bracelet RFID 108 prior to inserting the nozzle 92 into the nozzle sanitizing bath 117.
This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto. | In the inventive method for the sanitary rinsing of an animal, an assembly line is provided which includes a plurality of shackles. Each shackle includes an inventive RFID tag which includes a machine readable unique shackle number. Once an animal is stunned and attached to a shackle the animal is moved to a weighing station, which is equipped with an RFID tag reader, weighs the animal and transmits the weight and shackle number to a computer where the data is recorded in a database. The animal is then bled and moved to a rinsing station, which is equipped with an RFID tag reader which reads the shackle number. The system then looks up the weight of the animal to be rinsed at that particular rinsing station and calculates the amount of solution to inject into the circulatory system of the animal. After the end of the hose and nozzle and the operator's hands are sanitized, which is verified by the system, the nozzle is inserted into an entry point into the circulatory system and the operator starts the flow of the predetermined amount of solution into the animal. If the flow is not started within a time window, the operator must re-sanitize. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to metal roof systems and shingle roof systems that are used in both commercial and residential buildings and, more particularly, to vent coverings which allow for airflow and prevent foreign contaminants such as insects, birds, small animals and excess water from entering a roofing system by forming a partial seal.
[0003] 2. Description of the Prior Art
[0004] The life span of any roof will be increased if adequate ventilation is provided along the top vent of the roof. Ventilation is needed to allow air to flow through and out of the roof interior and out of the vent which is located along the top of the roof where the two slopes of the roof nearly meet. Having adequate airflow that uses roof ventilation is a proven construction technique that is used in both new construction and remodeling existing structures. Ventilation of the roof has been historically accomplished through the use of fabricated metal enclosures and complex fabricated plastic parts. In the 1970's, flexible reticulated polyurethane was used to achieve acceptable airflow and to solve the invasion of foreign debris small animals. While this material solved numerous problems, it still had several troubling shortcomings such as shrinkage, early deterioration, insufficient strength, low ultraviolet resistance, low tear resistance, density and low fire retardancy.
[0005] Beginning several years ago and in response to customer requests, research was directed to providing a better venting product than those then in use. Experimentation continued into the year 2000 and thereafter. Different materials were tested, but no acceptable version was identified until a few years ago when it was determined that reticulated polyurethane had the essential characteristics needed for a successful venting system. Later it was determined that this material when used would quickly begin to degrade because of poor ultraviolet resistance, poor hydrolytic stability, and the inability to meet building codes as a fire-retardant material used in construction.
[0006] More recently, a new, flexible, reticulated, polyurethane material was produced and, when tested, verified that it would prevent excess water from being driven by wind back through the ventilation material and into the roof interior. It was designed to withstand ultraviolet radiation for prolonged periods, and it was also designed to comply with building material standards and made fire resistant. The material proved successful and demonstrated that it would provide superior airflow for a roof and prevent wind-driven rain from entering the building. Thus an improved vented closure strip has been and continues to be very desirable, and it is to that end that the present invention is directed.
OBJECTIVES AND SUMMARY OF THE INVENTION
[0007] A primary objective of the present invention is to provide a roof venting system that has all of the advantages of prior art devices and more, and none of the disadvantages.
[0008] Another objective of the present invention is to enhance the outward flow of air from the region beneath the roof and at the same time inhibit the inward passage of moisture and insects.
[0009] Yet another objective of the present invention to provide a vent cover which engages a pair of laterally spaced open cell members so that air can freely flow outwardly therethrough while the entry of moisture and insects in a reverse direction is inhibited.
[0010] Still another objective of the present invention to provide foam members having a multiplicity of interconnected open pores so that maximum airflow is achieved and at the same time an optimum restriction to moisture and insects in an reverse direction is realized even when the moisture is in the form of wind-driven rain.
[0011] A further objective of the present invention is to provide a roof venting system that is readily conformable to the slope of the roof to which it is attached.
[0012] Yet another objective of the present invention is to provide sections of predetermined length, yet enabling any section to be cut to a lesser length during installation, such as when the last section must be shortened to match an end of the roof.
[0013] Yet another objective of the present invention is to provide a system having longevity through heat/cool cycles.
[0014] Still another objective of the present invention is to provide a system having hydrolytic stability.
[0015] A further objective of the present invention is to provide a system that will withstand oxidation.
[0016] Still another objective of the present invention is to provide an inexpensive roof vent system which will be virtually maintenance-free.
[0017] The invention in it broadest form is a roof venting system for covering a vent opening in the roof extending substantially for the length of the roof ridge permitting ventilation from the interior space under the roof to the exterior. The system includes a vent cover covering the vent opening extending over the opening for the length of the opening and overlapping the opening substantially evenly on each side. A pair of laterally-spaced, flexible, reticulated polyurethane foam members have first and second faces, the second faces engaging one side of the vent cover and the first faces engaging the roof profile.
[0018] Thus there has been outlined the more important features of the invention in order that the detailed description that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. In that respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its arrangement of the components set forth in the following description and illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways.
[0019] It is also to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting in any respect. Those skilled in the art will appreciate that the concept upon which this disclosure is based may readily be utilized as a basis for designing other structures, methods and systems for carrying out the several purposes of this development. It is important that the claims be regarded as including such equivalent methods and products resulting therefrom that do not depart from the spirit and scope of the present invention. The application is neither intended to define the invention, which is measured by its claims, nor to limit its scope in any way.
[0020] Thus, the objectives of the invention set forth above, along with the various features of novelty which characterize the invention, are noted 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 the specific results obtained by its use, reference should be made to following detailed specification taken in conjunction with the accompanying drawings wherein like characters designate like parts throughout the several views.
[0021] The drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. They illustrate embodiments of the invention and, together with their description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective, fragmentary view of the venting system of the present invention including the vent cover member, the foam members and the roof opening in a shingled roof;
[0023] FIG. 2 is an end elevational, partial view of the structure shown in claim 1 ;
[0024] FIG. 3 is a perspective and fragmentary view of the structure shown in FIG. 1 without the presence of the vent cover member and spaced-apart foam members;
[0025] FIG. 4 is perspective, fragmented and isolated view of the foam members engaging the strip;
[0026] FIG. 5 is a an end elevational view of two foam member having convoluted engaging surfaces made by cutting a single piece of foam;
[0027] FIG. 6 is a perspective view of the foam members with convoluted engaging surface spaced from each other;
[0028] FIG. 7 is a plan view of a single expandable foam member in a cut but unexpanded condition;
[0029] FIG. 8 is a perspective view of the form member shown in FIG. 7 in the cut and expanded condition being applied to a building over the ridge gable;
[0030] FIG. 9 is a perspective and fragmentary view of another embodiment of the present invention showing the placement of foam material over, in and for the length of the ridge vent;
[0031] FIG. 10 is a perspective and fragmentary view of the structure shown in FIG. 9 wherein two additional segments of foam material are positioned, one on each side of the ridge gable and the previously installed first segment of foam material;
[0032] FIG. 11 is an end elevational and fragmentary view of the structure similar to that shown in FIG. 10 which has a ridge cap covering the ridge gable and the foam material segments; and
[0033] FIG. 12 is an end elevational and diagrammatic view of the attic of a building showing the airflow entering the building and passing through the attic and back to the outside through the foam segments on each side of the ridge cap.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The present invention is more conveniently used with conventional sloping roofs such as are shown in FIGS. 1, 2 and 3 wherein a portion of one such roof shown generally as 10 includes rafters 12 and a ridge member 14 placed within the upper ends of rafters 12 and a collar beam 16 extending horizontally between each pair of rafters. Some roofs employ a truss construction not requiring a ridge member, and this roof is equally compatible with the invention. Sheathing 18 overlies rafters 12 , and over sheathing 18 is placed a layer of felt or building paper 20 . Roof shingles 22 are nailed through the felt 20 into sheathing 18 . A vent opening 24 permits the upward and outward flow of air in the direction of the arrows 26 ( FIG. 3 ) from the region beneath roof 10 such as an attic. Various vents (not shown) in the lower portion of the attic permit the ingress of air so that normal airflow is upwardly and outwardly through vent opening 24 as indicated by arrows 26 .
[0035] The primary embodiment of the present invention is illustrated in FIGS. 9, 10 , 11 and 12 . A foam member 28 is positioned between and slightly over the outside edges of sheathing upper edges 18 a and 18 b and substantially covers vent opening 24 . Additional foam members 34 , 36 are positioned on both sides of member 28 as shown in FIG. 11 . A ridge cap 29 is used to cover the ridge gable as shown in FIG. 11 , and the free ends 29 a , 29 b of cap 29 rest on members 34 and 36 . Cap 29 preferably is formed from a single piece of material and is secured to sheathing 18 by screws, rivets or nails.
[0036] Airflow within the system is shown in FIG. 12 where cool airflow from outside the building passes into the attic and replaces the moist and stale attic air which is moved to the outside through foam members 34 , 36 . Vent cover 28 and foam members 34 , 36 are formed in predetermined lengths such as eight-foot or twenty five-foot sections.
[0037] Another embodiment of the present invention is shown in FIGS. 1, 2 , 3 and 4 . Here a vent cover 30 is formed from a lightweight close-cell plastic such as reticulated polyurethane. The width of section 30 is approximately one foot and its thickness is approximately 0.5 to 1.5 inches. Its density can be approximately 1 to 1.7 pounds per cubic foot uncoated and 1.2 to 4 pounds per cubic foot coated. Member 32 is sufficiently flexible to readily conform to the slope or pitch of the roof as can be seen in FIG. 1 and FIG. 2 .
[0038] The foam members 34 , 36 of the primary embodiment and 34 a , 36 a of the second embodiment are laterally spaced with respect to each other in each embodiment to provide an intermediate space 38 . All members are formed of flexible, reticulated, open cell foamed plastic. The form's structure has numerous walls made of very thin polyurethane polymers. These walls are referred to as cell membranes. Cell membranes, even though they may be ruptured, block the free passage of air or fluids through the foam. After the foam has been produced, the cell membranes can be affected during a post thermal treating process. The very thin cell membranes are vaporized during this thermal treating process and leave only the foam strands or struts. The reticulation of polyurethane foam occurs as it is subjected to a proprietary process inside a specially designed vessel using heat and pressure to create flexible foam structures without cell membranes. The pentagonal dodecahedron, a geometric shape with 12 plane faces, is the natural structure of reticulated foam cells. The resulting fully open pore structure is now a reticulated foam which is highly permeable to the flow of air. The size of the open pores in the foam can be precisely controlled to allow void volumes up to 98%. The size of the pores and ruptured control the level of air permeability and determine the suitability of the foam to allow proper air flow, and the pores per inch (“PPI”) that work most effectively are in a range of 8 to 32 PPI.
[0039] The use of open cell members 34 , 36 , 34 a and 36 a function quite well to permit an unrestricted flow of air. The resistance to airflow is minimal. There is a need for an easy passage of air from beneath the roof, yet there is need for an effective resistance to the entrance of moisture, particularly wind-borne and snow, through members 34 , 36 , 34 a and 36 a . The presence of very fine interlinked filaments or strands prevent moisture from entering the building from the outside, even when the moisture is wind-driven, for the moisture collects on the various filaments or strands instead of entering the building.
[0040] While foam members 34 , 36 , 34 a and 36 a can be made as described, they would not have the ability to stand up to weathering (heat and cold) exposure. To overcome these shortcomings, coatings have been developed to prevent early disintegration and extend the life of this material. Coating the formed foam members with an acrylic latex such as provided as a straight up coating under the name Paranol AA-G-72 will extend product life cycle indefinitely during heating and cooling cycles, help reduce flame spread and enhance ultraviolet resistance. Coating the foam members with this chemical will prevent early breakdown of the foam due to exposure to sunlight. The acrylic polymer is naturally a superior molecular structure. The molecular bond formed in the acrylic is inherently resistant to ultraviolet radiation, and testing of this product to ASTM G53 criteria at 1000 hours has resulted in no visual surface degradation.
[0041] The foam members can be coated with a fire retardant substance containing or formed from antimony oxide that will prevent the spread of flames. In particular, another fire retardant derivative Decabromodiphenyl is a halogen, and as it burns, bromine molecules are released that push or force oxygen molecules away from the coating and thereby prevent oxygen from fueling the fire. This molecular composition has been known for many years.
[0042] The flexible reticulated polyurethane polymer foam can be produced in a basic version that will result in foam material having ultraviolet and flame resistant features without the application of any coating or before a coating is applied.
[0043] Foam members 34 , 36 , 34 a and 36 a are flexible and therefore will conform to contoured or corrugated surfaces without having to be cut to match the building or roof profile. The soft, flexible, conformable foam is pressed into the various contour panels and filling voids while still remaining porous.
[0044] Foam members 34 , 36 , 34 a and 36 a are made in a flat configuration that will be useable in many situation since the flat bottom surface will conform to many roof profiles. Another very important design consideration involves cutting the foam block into two separate pieces with a slitting device outfitted with a convolution roller to form convoluted surfaces on both cut foam surfaces. These foam convoluted surfaces readily conform to multiple structural profiles while making the passage of air therethrough even more efficient. See FIG. 6 and FIG. 7 . The convoluting cutting process leaves “egg crate” looking peaks and valleys in the convoluted surfaces.
[0045] An alternative embodiment of foam members 34 , 36 , 34 a and 36 a is the provision of a single expandable foam member 40 shown in FIG. 7 and FIG. 8 . Member 40 is cut as shown in FIG. 7 and then pulled laterally in an expansive manner to produce the expanded member 40 shown in FIG. 8 . This results in a user friendly single member 40 that requires less raw material while still providing superior ventilation.
[0046] During application to commercial, residential, other buildings and other structures, adhesive may be applied evenly along the entire length of the foam member material strip or roll. Conventional application has been to apply adhesive only in the valley's of fabricated vent material. The application of an adhesive to any of the foam members to securely engage them on the on either side with either the roof profile or the membrane is discretionary and subject to the direction of the construction director. In many cases, no adhesive is used.
[0047] From the preceding description, it can be seen that a roof venting system has been provided that will meet all of the advantages of prior art devices and offer additional not heretofore achievable. With respect to the foregoing invention, the optimum dimensional relationship to the parts of the invention including variations in size, materials, shape, form, function, and manner of operation, use and assembly are deemed readily apparent to those skilled in the art, and all equivalent relationships illustrated in the drawings and described in the specification are intended to be encompassed herein.
[0048] The foregoing is considered as illustrative only of the principles of the invention. Numerous modifications and changes will readily occur to those skilled in the art, and it is not desired to limit the invention to the exact construction and operation shown and described. All suitable modifications and equivalents that fall within the scope of the appended claims are deemed within the present inventive concept. | A roof venting system for removing warm and moist air from the interior of a building to the outside through a vent opening in the roof. The system includes a vent, cover member for placement over the vent opening and two foam members through which the indoor warm and moist air must pass when the air flows from the building interior to the outside. The foam members may be provided with a convoluted surface to facilitate close engagement to the roof profile, and a single piece foam may be used instead of the usual two. The foam and cover members may be flexible, reticulated polyurethane treated with one or more substances to enhance fire resistance and protect from heat/cold adverse weather. | 4 |
[0001] This application is a continuation of International Application No. PCT/US14/39336, filed May 23, 2014, which claims the benefit of U.S. Provisional Application No. 61/827,326, filed May 23, 2013, all of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is directed to a puncture resistant material made from consolidated layers of woven polypropylene fibers and nonwoven thermoplastic fibers. The puncture-resistant material has particular application in the manufacture of shoe soles.
[0004] 2. Description of the Related Art
[0005] The standard shoe sole protective material is steel, which continues to be the standard against which other shoe sole materials are judged for puncture resistance. However, a steel plate in a shoe lacks flexibility and is uncomfortable to wear. These drawbacks have been addressed to some extent by protective shoe sole materials made from fabric and fabric composites, as described in U.S. Patent Application Publication 2008/0222919, U.S. Pat. No. 6,167,639, and U.S. Pat. No. 5,896,680, for example. However, the prior art shoe sole materials all lack the desired combination of puncture resistance and flexibility at low weight and thickness. The inventors herein have discovered a technique for making a novel, highly puncture-resistant and flexible material from polypropylene and thermoplastic fibers which has application in the manufacture of puncture-resistant finished products, including but not limited to blast mitigation barriers, gloves, and shoe soles.
SUMMARY OF THE INVENTION
[0006] Thus, in one aspect, the invention is a puncture-resistant material, comprising one or more woven layers comprised of tightly woven yarns made from twisted high strength continuous filament polypropylene fibers and having a plurality of thermoplastic batting fibers needlepunched in a perpendicular direction into the woven layer(s) to form a substantially monolithic material. The density of the resulting monolithic material is increased by heat treatment and calendaring.
[0007] In another aspect the invention is a method for making a shoe sole material comprising the steps of: twisting high modulus polypropylene fibers to form continuous filament yarns; weaving said continuous filament yarns to form a tightly woven layer; placing batting material of thermoplastic fibers adjacent the woven layer; and needlepunching the batting material in a perpendicular direction into the woven layer to form a consolidated material. The consolidated material is heated above the glass transition temperature of the fibers to thermally shrink the fibers thus increasing the density of the material. The material is then calendared to further increase the density and form a puncture-resistant insole material.
[0008] In presently preferred embodiments, the thermoplastic fibers are polypropylene fibers.
[0009] In the preferred embodiments, the shoe sole material according to the invention is incorporated into a shoe sole as an insole material, i.e., inside an outer sole layer. In presently preferred embodiments, the insole material is positioned between an outer sole layer and one or more inner layers adjacent the wearer's foot. The preferred material according to the invention passes ASTM Standards 2412 and 2413 for puncture resistance. The protective shoe sole incorporating the material passes ASTM Standards 2412 and 2413 for flexibility.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is graphic depicting the performance of a shoe sole material in a puncture resistance test according to the present invention, compared to a steel plate.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Standards for protective footwear are described in ASTM F2413, entitled “Standard Specification for Performance Requirements for Protective (Safety) Toe Cap Footwear” and ASTM F2412, entitled “Standard Test Methods for Foot Protection.” Among other criteria, these standards set forth puncture resistance and flexibility requirements for a shoe sole material. Reference to a particular ASTM standard herein means the standard in effect on the effective filing date of this application. These standards set forth testing protocols for shoe sole materials generally recognized by those of ordinary skill in the art and are incorporated by reference.
[0012] The puncture resistant shoe sole material of the present invention is preferably used inside of an outermost layer of a shoe sole, i.e., as an insole material and is preferably in an intermediate layer, between an outer layer and an inner layer adjacent the wearer's foot.
[0013] The woven component of the material is formed from high strength polypropylene fibers.
[0014] To form the woven layer, the yarns are first twisted from 1 to 5 turns per inch to allow the material to be woven fairly tightly and act more like a monofilament. As an example, twisting may increase the denier of a polypropylene fiber yarn from 940d to 1150d. However, these results depend greatly on the denier of the starting material.
[0015] The yarns are woven to create a woven layer having a fairly tight weave, generally having greater than about 80% cover factor, and preferably greater than about 90% cover factor. A 25×25 plain weave has been found suitable, but is not critical. A 20×20 weave to about 30×30 weave is contemplated. In the embodiment of Example 1, a 24×24 weave is used.
[0016] From 1 to 20 woven layers, and preferably 5 to 9 woven layers are positioned with fiber batting material on one or both sides to form a stack. The stack is consolidated by needlepunching so that the batting material is forced into the interstices of the woven layer and forms a generally monolithic material.
[0017] The fiber batting material consolidated with the woven layers may be a batt of the same fibers used in the woven layers, or may be different. It is preferred to use high strength thermoplastic fibers, such as, without limitation, certain thermoplastic polyester fibers, polyamide fibers, poly(arylene sulfide) fibers; and high strength polypropylene and polyethylene fibers, all of which are available commercially and well characterized as to strength. Preferably 1-10 oz/yd 2 of batting fibers are used. In some instances, 5-8 oz/yd 2 has been found to be appropriate.
[0018] Heat treatment is conducted to increase the density of the consolidated material. Preferably, heat treatment is conducted to a temperature slightly above the glass transition temperature of the thermoplastic fibers to partially melt the thermoplastic fibers. The thermoplastic fibers are not substantially completely melted to form a matrix, as might be expected forming a fiber composite, but the thermal shrinkage tightens the weave even more and partially melts the through thickness fibers to bond the system together. The density of the material is preferably increased in a range of about 5% to about 20%. In some cases, it is desired to increase the density in a range of about 8 to about 15%. In presently preferred, but non-limiting embodiments, the density is increased about 10 to 12%. In the case of certain polypropylene fibers, the heating step is preferably conducted in a dryer at a temperature in the neighborhood of 320° F.
[0019] Calendaring further increases the density of the material and reduces the thickness of the material to about 0.05 to about 0.35 inches, preferably about 0.10 to about 0.20 inches, which is considered suitable for most shoe insole applications. The weight of the insole material is preferably 50-120 oz/yd 2 , more preferably 65-75 oz/yd 2 .
[0020] The material is incorporated into a protective shoe by cutting the puncture resistant material to form an insole profile covering substantially the inside bottom surface of a shoe to form a puncture-resistant barrier. Preferably, the material is an insole material, intermediate an inner layer and an outer sole layer.
EXAMPLE 1
[0021] Highly drawn and high strength INNEGRA® brand polypropylene continuous filament yarns having a denier of about 940d were twisted fairly aggressively—about 2.5 turns per inch (TPI)—and woven into an approximately 24×24 plain weave. Six of the woven layers were arranged in a stack, and a batt of similar polypropylene fibers was arranged on the top and bottom of the stack and consolidated with the woven layer by needlepunching. The consolidated material was heat set in an oven at 320° F. to shrink the materials significantly. The resulting material was calendared under heat and pressure low enough not to significantly impact the physical properties of the fibers, but sufficient to reduce the thickness and smooth the surface. Before arranging in a shoe insole, the resulting material has a thickness of about 0.170 inches, a weight of about 67.5 oz/yd 2 and passes ASTM 2412/13 for puncture resistance. Arranged as an intermediate layer in a shoe sole, the resulting product passes ASTM 2412/13 for flexibility.
[0022] FIG. 2 shows the penetration resistance of a material according to Example 1 compared against a standard steel shoe sole material having a thickness selected to pass ASTM 2412/13.
[0023] The above description of the preferred embodiments is not to be deemed limiting of the invention, which is defined by the following claims. The foregoing description should provide the artisan of ordinary skill with sufficient information to practice variants of the embodiments described. Features and improvements described in connection with one embodiment or one claim may be combined with other embodiments or other claims without departing from the scope of the invention. | A puncture resistant material is made from high modulus continuous filament polypropylene yarns which are twisted and woven into a tight weave. Batting materials are placed adjacent the woven layer (which may comprise one or more individual woven layers) to form a stack and the stack is needlepunched to form a consolidated material. The material is heat treated and calendared and the finished product may be used in applications where puncture resistance is required, such as in a shoe insole material. | 3 |
BACKGROUND OF THE INVENTION
The invention relates generally to a packing system and more particularly to material for sealing and preventing leakage around pump shafts, rods and the like.
Many industrial processes use a water suspension system to move materials or manufacture final products. Examples of industries where this is common include paper manufacturing, domestic and industrial waste disposal and mining. Each of these industries employ processes where suspensions are moved with pumps. Other industrial processes employ pumps to move large quantities of liquids for various other purposes.
A conventional pump includes a motor and some sort of impeller, such as a blade or piston. The motor is typically outside of the flow of fluid and the impeller is typically exposed to the flow of fluid. Energy is typically provided from the motor to the impeller through a shaft or rod. It is thus necessary to seal the fluid being pumped from the opening for the shaft, while permitting the shaft to spin or reciprocate at high speeds for long durations of time.
One method of sealing shafts is to provide a mechanical seal in the form of a high precision machined rotating disk with a matching sealing face precisely fitted to the rotating shaft. However, such a construction is expensive to manufacture, frustrating to maintain and difficult to repair. Thus, the use of such mechanical seals is limited.
A more common approach is to employ a stuffing box filled with a conventional braided packing material. Such material surrounds the shaft and permits the shaft to rotate therein while substantially preventing liquids or gases from leaking out of the pump housing. Conventional stuffing boxes for many pumps are designed to permit a small amount of fluid to leak through the stuffing box and out of the pump. The fluid leakage is permitted to increase the lubrication properties of the stuffing material and provide for heat transfer. When dangerous or inconvenient fluids or suspensions are being pumped, it is also common to provide the stuffing box with a water inlet, to permit water flow through the stuffing box, isolating the problem fluid, while allowing leakage of water to provide lubrication and cooling of the packing.
In each of these conventional operations involving the controlled leakage of liquid through the packing material, it is not uncommon for 1-3 gallons per day or more of liquid to be consumed and/or leak out of the stuffing box. For a facility having 1,000 pumps or more, it is clear that the total daily amount of liquids leaking from pumps can be quite high.
In recent years, the cost of water in most industrial processes has risen significantly and the cost of cleaning up the wastewater of industrial processes has risen even more. During the manufacture of paper, the treatment of domestic and industrial waste and mining, much of the water leaking through normal braided packing installations is contaminated and requires significant cleanup procedures before it can be discharged back to natural sources, such as rivers, lakes and streams. Vapors and other undesirable emissions are also permitted to escape from conventional pumps and valves.
Accordingly, it is desirable to provide a packing material that can overcome drawbacks of the prior art.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the invention, a substantially leak free waterless packing material and system are provided for sealing pump shafts and the like. The packing is manufactured from twisted, exfoliated, extruded, pultruded or slit graphite material that is braided, twisted, laid up or otherwise combined to form mechanical packing. A lubricant and/or sealant may be applied to the finished packing. Graphite foil may be applied to the packing for enhanced properties. The packing preferably is formed with at least three rings including compressible graphite packing, the rings compressed to different percentages of their original heights. The outside rings will have the most compression and the inner ring or rings of the multi-ring assembly the least. All should be compressed less than the maximum amount possible to permit high conformance to the surface being sealed.
Accordingly, it is an object of the invention to provide improved packing material.
Another object of the invention is to reduce or eliminate the amount of leakage of liquids and vapors from pump seals.
Another abject of the invention is to eliminate the need for a flush or barter fluid, injected into the middle of the stuffing box, resulting in the dilution of the process fluid and additional leakage from the pump or rotating shaft.
A further object of the invention is to provide an improved method of manufacturing packing material.
Still another object of the invention is to provide an improved packing product to significantly limit or eliminate leakage through seals.
Yet another object of the invention is to provide an improved packing material that can be used in a conventional stuffing box and operated with little or no leakage of liquid past the packing.
Still other objects and advantages of the invention will be in part obvious and will in part be apparent from the specification and drawings.
The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the article possessing the features, properties, and the relation of elements, which are exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a cross-sectional view of a stuffing box for a pump or other rotating shaft packed with packing material in accordance with an embodiment of the invention;
FIGS. 2A, 2B and 2C are cross-sectional views of packing material in accordance with an embodiment of the invention in relative stages of compression;
FIG. 3 is a perspective view of an expanding inner bushing for use in a packing assembly in accordance with an embodiment of the invention; and
FIG. 4 is a cross-sectional view of the bushing of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A flushless and waterless packing assembly in accordance with the invention is intended to operate with little or no leakage past the packed seal. Whereas conventional braided packing is generally operated with some leakage to permit heat transfer and enhance lubrication, packing in accordance with the invention has suitable heat transfer properties and a suitably low co-efficient of friction that it can be operated with minimal or even no leakage. The improved sealing assembly in accordance with the invention relies on a specially prepared mechanical packing or a combination of specially prepared packings that can be installed with an improved expanding inner bushing and a thin follower ring.
Referring to FIG. 1, a flushless waterless packing assembly 100, constructed in accordance with a preferred embodiment of the invention is shown installed in a stuffing box 150 around a shaft 160. To install packing assembly 100, stuffing box 150 having a rear wall 151 is opened by loosening a set of gland nuts 71 and removing a gland follower 170 from stuffing box 150. All old packing, if any, is removed and stuffing box 150 is cleaned, if necessary. Assembly 100 is then installed over shaft 160 by first installing an optional wedge set expandable bushing 300, shown in FIGS. 3 and 4. Wedge set 300 includes a female or concave half 301 and a male or convex half 302.
Convex half 302 is slipped over shaft 160 and a flat side 321 of convex half 302 is positioned against rear wall 151 of stuffing box 150. Afterwards, convex half 301 of wedge set 300 is slipped over shaft 160 and positioned so that a convex face 320 of male half 302 nests in a concave or cupped face 311 of female half 301. Wedge set 300 can also be positioned with back wall 310 against rear wall 151. A back wall 310 of concave half 301 is flat and presents a surface perpendicular to shaft 160. Wedge set 300 is advantageously made from a glass/TEFLON composite, with a small amount of molybdenum therein. Such material can be obtained from Industrial Fluoroplastics of Salt Lake City.
A highly compressed end ring 510a of assembly 100 is then slipped over shaft 160 and pushed against back wall 310 of wedge set 300. If wedge set 300 is not used, end ring 510a is disposed against end wall 151 of stuffing box 150. An alternate bushing or washer, similar to gasket washer 400, may be used instead of or in addition to wedge set 300. One or more moderately compressed packing rings 520 (in this case three) are then slipped over shaft 160 and pushed against highly compressed packing ring 510a. Thereafter, a second highly compressed packing ring 510b is slipped over shaft 160 and against the last moderately compressed ring 520. A gasket washer 400 can then be slid against highly compressed packing ring 510b. Gasket 400 can be made of the same material as wedge set 300.
After packing assembly 100 is installed in stuffing box 150, gland follower 170 is replaced and packing assembly 100 is compressed by tightening gland nuts 171. Gland nuts 171 should not be over tightened in order to prevent damaging packing assembly 100.
The packing or combinations of packings of the invention can be manufactured from carbon fibers having graphite particles disposed thereon. The graphite particles are in a foamed or expanded form which is substantially inelastically compressible. The packing substantially will not return to its original dimensions after compression the way polymer foams, such as styrofoam will, after styrofoam is compressed. Such packing also has substantially the same thermal coefficient of expansion as metal and the packing assembly of the invention will therefore maintain its excellent seal as the shaft changes temperature.
A preferred exfoliated graphite yarn for forming packing material in accordance with an embodiment of the invention can be manufactured by heating high purity graphite crystals to a temperature over about 1500° F. This causes a rapid accordion-like expansion of the crystals. Upon cooling, a slurry of the expanded crystals are extruded, pultruded or coated about an approximately 96% pure graphite carrier yarn to form the final yarn to be braided or otherwise combined. The yarn is then sized and stabilized, removing excess flakes of graphite in the process.
These exfoliated graphite yarns are then braided, twisted, laid up or otherwise combined to form a continuous rope of packing material. A core of inorganic fiber combined with Inconel wire with preferably dried but unsintered polytetrafluoroethylene (PTFE) and pure carbon particles thereon or packing braided with inorganic fiber/PTFE yarns or fibers can provide packing material with additional resilience and greater resistance to vapor flow. Such inorganic fiber/PTFE material is described in U.S. Pat. No. 4,431,648, the contents of which are incorporated herein by reference. The rope of braided yarn can then be diagonally cut to size to fit around a shaft of selected diameter and shaped in a die to form a ring of packing material such as packing ring 200 shown in FIG. 2A. The cross-sectional height of packing ring 200 is reduced by compressing ring 200 in a die to form moderately compressed packing ring 200' of FIG. 2B. Additional compression leads to a highly compressed packing ring 200" shown in FIG. 2C.
Unlike conventional packings, packing rings formed in accordance with the invention should not be fully compressed prior to installation. Thus, neither ring 200' nor ring 200" should be in a fully compressed state. Because the rings are not fully compressed prior to installation, they can mold to the precise dimensions of a shaft or packing box during installation and provide an essentially water tight seal. Nevertheless, the use of additional rings in a fully compressed state is not precluded.
In a preferred embodiment of the invention, graphite foil, such as a product sold under the trademark GRAPHOIL, by Union Carbide, is formed around an inner wall 210 of ring 200 prior to compression. The graphite foil is advantageously extended only 25% to 75% up a side wall 220, towards outer wall 230. It is preferable not to wrap the graphite foil completely around all walls of ring 200.
In a preferred method of manufacturing a packing ring assembly in accordance with the invention, a set of at least three rings and preferably 5 to 7 rings are cut to size. Graphite foil is then applied to what will be the inner wall of the packing rings which will rub against the pump shaft and partially up the side walls. Thereafter, the rings that are intended to be the two outside rings of a multi-ring packing assembly are compressed in the die to about 80% of their original height. Compressions of about 75 to 85% are acceptable, as long as the material is not compressed to the fullest extent. The material for one of the inner rings of a multi-ring packing assembly is compressed to only about 90% of its original height. Compressions of about 85 to 95% have been found to be acceptable. Preferred exfoliated graphite packing material can typically be compressed to a maximum of about 65 to 70% of its original height in either normal installation or die forming operations. Thus, the compression amounts should be less than this to insure that the rings will mold to shape during installation.
The inner and outer packing rings are formed with different compression levels for the following reasons. As the gland follower compresses the packing assembly, the inner rings, because they are easier to compress, deform first. The higher initial compression of the outer rings aids both in the uniform compression of the inner rings and in preventing extrusion of the softer inner rings around the wedge set, gasket washer or stuffing box. The graphite foil on the inside wall of all rings presents a low friction, impermeable rubbing surface to the shaft being sealed. The packing assembly also exhibits an extremely high heat transfer coefficient. Thus, the assembly can be run dry, with suitable friction and heat transfer properties.
Because the rings of the packing assembly of the invention have considerably less initial compression than a conventional die formed packing set, the rings, in particular the inner rings, will seat extremely well to the bore of the stuffing box and to the shaft. Thus, tightening of the gland nuts permits additional deformation of the packing as required to completely fill any minute voids in the stuffing box while properly conforming to the shaft. The configuration and construction also permits a substantially uniform unit loading to all portions of the seal. This additional tightening capability will also permit the packing of the invention to conform better to worn or slightly irregular shafts.
The expanding inner bushing helps prevent the extrusion of any of the packing material into the throat or base of the stuffing box around the shaft of the device. It also helps limit the amount of suspended particles in the media being sealed, from entering or contacting the packing around the shaft. This minimizes wear on the shaft and possible damage to the inside diameter of the packing. The optional thin gasket washer helps ensure a more uniform load as well as minimize any extrusion of the inner or outer wall of the last packing ring, in the case of an imperfect seal between the gland follower and shaft or stuffing box.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in carrying out the above method and in the article set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | A minimum leakage packing system is provided for sealing pump shafts and the like. The packing is manufactured from twisted, exfoliated extruded, pultruded or slit graphite material that is braided, twisted, laid up or otherwise combined to form mechanical packing. A lubricant and/or sealant may be applied to the finished packing. Graphite foil may be applied to the packing for enhanced properties. The packing system preferably consists of a precision wedge set and at least three rings including compressible graphite material, the rings compressed to different percentages of their original heights. The outside rings will have the most compression and the inner ring or rings of the multi-ring assembly the least. All should be compressed less than the maximum amount to permit high conformance to the surface being sealed. The system may have an optional gasket washer following the last ring of compressed graphite material. | 5 |
TECHNICAL FIELD
This invention relates to sharpeners for the rotary cutting cylinder of crop harvesters.
BACKGROUND ART
The peripherally located knives of such cylinders require frequent sharpening in order to obtain the desired uniformity in chop length of crop materials being passed through the cylinder and to minimize the horsepower requirements associated with the cutting or chopping operation. At the same time, however, it is desirable to carry out such sharpening operation in a fast, effective and yet safe manner.
SUMMARY OF THE PRESENT INVENTION
Accordingly, the present invention contemplates a sharpener which is so designed that, it is operated remotely and while the cylinder is rotating so that convenience and speed are maximized, while the time expended in actually effecting the sharpening without performing harvesting operations, is held to a minimum. Furthermore, recognizing that the metal of the knives is progressively ground away during successive sharpening operations, the sharpener of the present invention is provided with a special indexing arrangement by which the sharpener is allowed to position itself slightly closer to the axis of rotation of the cylinder each time the sharpener is brought into engagement with the knives. A cover associated with the sharpener is adapted to alternately close off and expose the opening in the housing through which the sharpener projects during engagement with the knives, and such operation of the cover is made responsive to movement of the sharpener between its standby and sharpening positions so as to close the opening and not interfere with harvesting operations when the sharpener is idled but to then expose the opening for the sharpener when it is time to temporarily interrupt the harvesting operations and prepare the cutting edges of the knives.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side elevational view of the cutter box on a crop harvester having a sharpener assembly in accordance with the principles of the present invention mounted thereon;
FIG. 2 is a slightly enlarged, vertical cross-sectional view through the sharpener assembly of FIG. 1 showing the abrasive stone thereof in its standby position with the cover closing the access opening to the cutting cylinder;
FIG. 3 is a fragmentary elevational view of the cutter box and sharpener assembly of FIG. 1 but illustrating the condition of components on the outside of the assembly when the sharpening stone is down in engagement with the knives of the cylinder;
FIG. 4 is a fragmentary cross-sectional view of the sharpening assembly taken substantially along line 4--4 of FIG. 3 when the stone is in its sharpening position;
FIG. 5 is a fragmentary elevational view of the opposite side of the cutter box and sharpener assembly;
FIG. 6 is an enlarged, fragmentary, detail cross-sectional view of a portion of the indexing apparatus at one end of the sharpener taken substantially along line 6--6 of FIG. 4.
FIG. 7 is a fragmentary, vertical cross-sectional view of the sharpener assembly similar to FIG. 2 but with the stone in its sharpening position and the cover exposing the access opening to the interior of the cutter box;
FIG. 8 is an enlarged, fragmentary detail view of other portions of the index apparatus and limit stop arrangement for determining the position of the sharpening stone during each movement thereof into engagement with the knives, parts being shown in cross-section and in elevation to reveal details of construction; and
FIG. 9 is a transverse cross-sectional view through the one-way clutch of the indexing apparatus taken substantially along line 9--9 of FIG. 6.
DETAILED DESCRIPTION
The cutter box 10 of the harvester broadly includes a housing 12 having a cutting cylinder 14 rotatably mounted therein for high speed rotation about an axis 16. A plurality of elongated knives 18, extending generally parallel to the axis 16, are mounted at the periphery of the cylinder 14 in circumferentially spaced relationship for cooperation with a stationary shear bar 20 in chopping or cutting crop materials into countless small segments as they are fed into the housing 12 generally in the direction of the arrow 22 in FIG. 1. An adjustment assembly 24 as shown in FIG. 1 may be coupled with the shear bar 20 for permitting the operator to adjustably shift the shear bar 20 toward and away from the cutting cylinder 14.
The sharpener assembly 26 of the present invention is mounted on the cutter box 10 and attached to the top wall 28 thereof directly above an access opening 30 in the top wall 28 as illustrated particularly in FIGS. 2 and 7. The assembly 26 itself broadly includes a frame or chassis 32 to which other components of the assembly 26 are attached, including a hood 34 defining an internal chamber 36 normally closed by an outwardly bowed door 38 which is swingable about a hinge 40 between open and closed positions.
A special rocking carrier 42 is housed within the chamber 36 and has an axis 43 of rocking movement or rotation (FIGS. 2 and 7) defined by a pair of stub shafts 44 and 46 which project outwardly from opposite ends thereof for rotational support by corresponding bearing assemblies 48 and 50. The bearing 50 is supported by an endwall 52 of the hood 34 while the bearing 48 is supported by an adjustable end plate 54 as shown in FIG. 5 which, in turn, is attached to an opposite endwall 56 of the hood 34. By releasing set screws 58 and 60 which pass through vertically elongated slots 62 and 64 respectively in the end plate 54 to secure the same to the endwall 56, the end plate 54 may be selectively adjusted upwardly or downwardly by appropriately turning a nut 66 associated with a threaded bolt 68 that couples the plate 54 with an upper extremity of the endwall 56. A lock 70 associated with the bolt 68 should also be loosened and subsequently retightened in connection with the plate adjustment.
As shown perhaps best in FIG. 4, the opening 30 extends substantially completely across the housing 12 of the cutter box 10, and it is to be understood that, likewise, the cutting cylinder 14 substantially spans the two opposite sides of the housing 12. Thus, it can be seen and will be appreciated that, as shown in FIG. 4, the carrier 42 overlies the opening 30 along the full length of the latter and slightly beyond the opposite end extremities thereof whereat it is supported by bearings 48, 50 and the endwalls 52, 56.
A cylindrical grinding stone member 70 only slightly shorter than the length of the opening 30 is secured to the carrier 42 for rocking movement therewith about the axis 43. The stone 70 is maintained with its longitudinal axis in parallelism with the rocking axis 43 and has a central core shaft 72 having opposite stub ends 72a and 72b as shown in FIG. 4 which are releasibly held by a pair of clamps 74 and 76 (FIG. 4) at opposite ends thereof. The clamps 74, 76 securely hold the stone 70 on the carrier 42 for rocking movement therewith yet, when loosened, permit the stone 70 to be adjustably rotated about its longitudinal axis to expose a different portion of this periphery for knife engagement during the sharpening operation as will hereinafter become apparent.
As shown perhaps most clearly in FIGS. 2 and 7, the stone 70 is supported by the carrier 42 at a distance from the rocking axis 43, or on one side thereof. On the other side of the axis 43, a long rod 78 is supported by the carrier 42 in parallel relationship to the axis 43. The rod 78 extends the full length of the carrier 42 and is pivotally supported at its opposite ends by end extremities of the carrier 42 such that the rod 78 can pivot about its longitudinal axis. Thus, the rod 78 serves as a hinge pin for a slightly arcuate cover plate 80 having a length substantially corresponding to that of the opening 30 and a width slightly exceeding that of the opening 30. The cover plate 80 has an upturned marginal edge 80a along one longitudinal extremity thereof which is welded or otherwise permanently affixed to the rod 78 so that the cover plate 80 is rendered swingable about the longitudinal axis of the rod 78.
As illustrated in FIG. 7, the cover plate 80 hangs freely from the rod 78 in a substantially upright manner when the carrier 42 is in the grinding position, but when the carrier 42 is in a standby position as illustrated in FIG. 2, the cover plate 80 overlies and closes off the opening 30. A pair of upwardly arched guide rails 82 and 84 (FIGS. 2, 4 and 7) are situated at opposite ends of the opening 30 just above the latter on the housing 12 in position to guide and slideably receive opposite end extremities of the cover plate 80 as the latter swings from its vertically depending position in FIG. 7 to its generally horizontal, covering position of FIG. 2. A slightly upturned retainer 86 along the leading edge of the opening 30 as shown in FIGS. 2 and 7 snuggly receives the cover plate 80 thereunder when it is in the covering position of FIG. 2.
The carrier 42 with its stone 70 and cover plate 80 is rocked about the axis 43 by apparatus broadly denoted by the numeral 88, such apparatus 88 being operable not only to rock the stone 70 back-and-forth between its grinding end standby positions, but also to locate the stone 70 slightly closer to the cutting cylinder 14 each time the stone 70 is rocked down into sharpening position. As illustrated in FIGS. 1 and 3, the apparatus 88 includes in part a reversible electric motor 90 having an upwardly and forwardly inclined output shaft 92 of which a worm 94 forms a part. The worm 94 in turn meshes with a gear 96 which is, in turn, keyed to the stub shaft 46 of the carrier 42 as illustrated in FIG. 6, thus supplying driving power to the latter. An arcuately shaped abutment 98 fixed to the gear 96 for rotation therewith and projecting outwardly therefrom is disposed to cooperatively engage an upstanding stop 100 and thereby limit the extent of clockwise rotation of the gear 96 viewing FIG. 1. When the abutment 98 is spaced away from the stop 100 as shown in FIG. 1, the carrier 42 maintains the stone 70 in its standby position with the cover plate 80 closing the opening 30, all as shown in FIG. 2. On the other hand, when the abutment 98 is situated against the stop 100 as illustrated in FIGS. 3 and 8, the carrier 42 will position the stone 70 down into the opening 30 in its sharpening position with the cover plate 80 retracted, all as shown in FIG. 7. Preferably, the motor 90 is operated by a remote switch (not shown) which may advantageously be located in the cab of the vehicle associated with the harvester, it being contemplated that the motor 90 will remain actuated for so long as the switch is closed in either of its alternative positions for rocking the stone 70 toward or away from the cylinder 14.
The apparatus 88 also includes mechanism broadly denoted by the numeral 102 for incrementally adjusting the position of the stop 100, and thereby also adjusting the sharpening position of the stone 70 in the opening 30, upon a predetermined number of rocking movements by the stone 70. Preferably, such adjustment of the stop 100 occurs after each sharpening operation. In other words, each time the stone 70 is brought into sharpening engagement with the knives 18, it will be in a slightly lower position, closer to the cylinder 14, than during the previous sharpening operation.
To this end the mechanism 102 includes an extension 104 of the carrier shaft 46 (FIG. 6) which carries a sleeve-like housing 106 at its outer end. As illustrated, the housing 106 is adapted to rotate with the shaft extension 104 by virtue of a cross pin or bolt 108. The mechanism 102 also includes a one-way roller clutch 110 contained within the cavity 112 of housing 106 in circumscribing relationship to the reduced diameter portion 114 of a sleeve 116 slideably rotatable on the shaft extension 104. The clutch 110 may be of the type provided by the Torrington Company of Torrington, Conn. under its part number "RC-121610". The outer casing 118 of the clutch 110 is pressed into the cavity 112 of housing 106 and is thus adapted to rotate with the latter in both directions of its rotation while, on the other hand, the inner race 120 of the clutch 110 is adapted to rotate with the outer casing 118 in only one direction, i.e., when the casing 118 rotates in a counterclockwise direction viewing FIGS. 1 and 3 as the stone 70 is rocked up out of the opening 30. Inasmuch as the inner race 120 is secured to the reduced diameter portion 114 of the sleeve 116, the latter is clutched by the one-way clutch 110 to rotate with the housing 106 only during the aforementioned counterclockwise rotation thereof.
The sleeve 116 is also provided with a worm portion 122 situated inboard of the reduced diameter portion 114. A spacer collar 124 encircles the shaft extension 104 between the inboard end of the worm portion 122 and the outboard end of the larger diameter shaft 46.
The mechanism 102 additionally includes a worm gear 126 meshing with the worm portion 122 and rotatably supported at the outer end of a hollow pedestal 128 secured to and projecting upwardly from the chassis 32 of the sharpener assembly 26. The gear 126 has a polygonal bore 130 disposed axially therethrough which receives the stop 100, the latter having a series of flat faces 132 thereabout corresponding in number and in general dimensions to those of the polygonal bore 130 such that rotation of the gear 126 causes corresponding rotation of the stop 100. On the other hand, the stop 100 is axially slideable through the bore 130 and has a lower, threaded shank 134 which is matingly received by an internally threaded lower portion 136 of the pedestal 128.
OPERATION
The stone 70 is normally maintained up out of the opening 30 in its standby position as illustrated in FIG. 2, at which time the abutment 98 is spaced from the stop 100 as shown in FIG. 1. The cover plate 80 at this time is securely held in its FIG. 2 position closing the opening 30. The cutting cylinder 14 rotates in a clockwise direction at this time viewing FIG. 2 in order to cooperate with the shear bar 20 in chopping incoming crops along the path of travel indicated by the arrow 22 of FIG. 1 into countless small segments of predetermined length.
If it is then desired to sharpen the knives 18 the operator should not stop the cylinder 14, although it is preferable to halt forward progress of the harvester itself.
With the cylinder 14 spinning, the operator moves the motor control switch (not shown) to the appropriate position so as to energize the motor 90 in a manner to rotate the gear 96 and thus rock the carrier 42 in a clockwise direction from its FIG. 2 position toward its FIG. 7 position. Inasmuch as the stone 70 is on one side of the axis 43 and the cover plate 82 is on the opposite side of the axis 43, such motion by the carrier 42 simultaneously causes the cover plate 80 to be drawn up away from the opening 30 and the stone 70 to be moved down toward the now exposed opening 30. This action continues until the abutment 98 strikes the upper tip of the stop 100 as shown in FIG. 3, at which time the operator may release the switch.
With the stone 70 thus projecting down through the opening 30 as shown in FIG. 7 into the path of travel of the knives 18 of the spinning cylinder 14, the lowermost periphery of the stone 70 will grind against the leading edges of the knives 18 to sharpen the same.
After the knives have been adequately sharpened, the operator may then throw the control switch into the proper position for withdrawing the stone 70 and replacing the cover plate 80. Such positioning of the control switch energizes the motor 90 in the reverse direction so that the gear 96 thereupon rotates in a counterclockwise direction viewing FIGS. 1 and 3 to correspondingly rock the carrier 42 counterclockwise.
It is during the retraction or withdrawal of the stone 70 from the opening 30 that the stop 100 is indexed downwardly by a predetermined increment so that on the next movement of the stone 70 toward the cylinder 14, the stone 70 will project slightly further through the opening 30 than during the immediately preceding sharpening operation. In this respect, it may be seen that as the shaft extension 104 of the carrier 42 rotates counterclockwise during return of the stone 70 to its standby position of FIG. 2, the one-way clutch 110 drivingly engages the housing 106 with the sleeve 116 so as to rotate the worm portion 122 thereof and correspondingly cause rotation of the stop 100 via the worm gear 126. Such rotation of the stop 100 causes the same to be threaded down into the pedestal 128 by an increment of travel dependant upon the thread pitch of the shank 134. Thus, the next time that the abutment 98 engages the stop 100, the latter will be slightly lower than during the previous operation, permitting the stone 70 to correspondingly protrude slightly further through the opening 30.
As noted earlier, the one-way clutch 110 prevents retrograde rotation of the worm portion 122 as the shaft extension 104 rotates in a clockwise direction when the stone 70 is being rocked down toward the opening 30. Consequently, the stop 100 is only progressively lowered, never raised.
It is to be appreciated that the operator may, if he so desires, adjust the position of the stop 100 more than once during the time period that he is sharpening the cylinder 14. It is only necessary in this respect that the rocking cycle of the carrier 42 be repeated a number of times corresponding to the amount of stop adjustment desired.
It will also be appreciated that the periphery of the stone 70 will become progressively worn away and flattened. By lifting the door 38, access may be gained to the clamps 74 and 76 for rotatively adjusting the position of the stone 70 as may be necessary or desirable. | The cutter box which houses a cutting cylinder on a harvester has an access opening in its top wall through which an abrasive, full-length sharpening stone may be alternately inserted and removed to engage and sharpen the peripherally located knives of the cylinder as the latter is rotated. Each time the stone is rocked down into the opening for a sharpening operation, it is indexed slightly further into the opening than during the previous operation in order to accommodate the slightly reduced diameter of the cylinder due to material which has been removed from the knives and the stone during the previous sharpening operation. A cover coupled with the stone is caused to move into closing relationship with the opening as the stone is rocked out of the same and, conversely, to pull away from and expose the opening as the stone is subsequently reinserted. All of the mechanical movements involved, including indexing of the stone, may be accomplished remotely through the use of an electric motor. | 0 |
This application claims the benefit of Prov. Appl. No. 60/167,424, filed Nov. 24, 1999.
BACKGROUND—FIELD OF THE INVENTION
This invention relates to charged particle storage rings and radiation sources, specifically to sources using radiation from the perturbation of relativistic charged particles. The invention provides a way to increase the total electron or charged particle flux available for use with radiating targets in a storage ring.
BACKGROUND—Prior Art
It has been considered by many that it is impossible to inject an electron into a magnetic storage ring from an external location without the use of time-varying, inhomogenous magnetic fields or synchrotron radiation. (D. W. Kerst and R. Server, Phys. Rev., vol. 60, pp.53-58, 1941.) An electron or other charged particle launched into a static magnetic field from a point exterior to that magnetic field and which experiences no acceleration other than that provided by the static magnetic field cannot subscribe to a path completely contained within that field. Charged particles are trapped into magnetic storage rings by either modifying the magnetic field while the particle is in the storage ring, by such means as a “kicker” magnet or perturbator, or by modifying the energy or trajectory of the charged particle. For instance, the synchrotron radiation emitted by high energy electrons in a large magnetic storage ring slows the particle, increasing the effective force of the magnetic field, and giving the magnetic storage ring the turning power needed to capture the electron. Kicker magnets and perturbators are used to modify the magnetic field to capture the electrons.
Another method used to capture electrons or other charged particles in a storage ring is to inject the particles from a point inside the ring. This method is used in betatrons.
Prior Art—Kicker Magnets
Electromagnets capable of changing the strength of their magnetic field quickly, often called “kicker” magnets are used to capture externally injected charged particles in a magnetic ring such as a synchrotron. For a magnetic ring of 10 meters diameter, the travel time around the ring is 100 nanoseconds. In addition, betatron oscillations will prevent the electron from returning close to its point of injection for several cycles, allowing the kicker magnet a time on the order of microseconds to switch. For small magnetic storage rings, of diameter 1 meter or less, the travel time for one orbit around the ring is on the order of 10 nanoseconds, which is makes kicker magnets prohibitively difficult and expensive to produce. The difficulty increases with decreasing radius. Examples a such systems can be found in U.S. Pat. Nos. 5,789,875, 5,216,377 and 5,001,437.
Prior Art—Perturbators
Perturbators are generally air-core coils that generate a non-linear magnetic field in the radius vector direction (see U.S. Pat. No. 5,680,018). They are similar to kicker magnets, but use a weaker field, allowing their use with smaller storage rings. Using a method called resonance injection, the perturbator is driven for a period on the order of 100 nanoseconds, allowing electron capture during this time. The perturbing field increases the betatron oscillations of injected particles, keeping them away from the point of injection for multiple orbits. When the perturbator is turned off, the beam size decreases and the betatron oscillations decrease due to radiation damping, with particles settling on a center, equilibrium orbit. The perturbator can be constructed to minimize disturbance to particles already at the equilibrium orbit. Thus, the perturbator can be pulsed again, allowing further injection, only after sufficient radiation damping to move the already injected particles away from the perturbing magnetic field. Typically this allows injection pulses at a repetition rate of 100 Hz, for a duty cycle of 10 −9 . This method does not allow for truly continuous injection (a 100% duty cycle) and requires, like a kicker magnet, a complex, rapid magnet pulse system.
Prior Art—Synchrotron Radiative Loss
The energy lost by an electron or other charged particle as it accelerates (turns) in the magnetic field can be used to slow the particle and allow its capture. This is in part used for resonant injection with a perturbator. However, the energy emitted by a charged particle as synchrotron radiation varies as the fourth power of the electron energy. More precisely, for electrons the energy loss due to synchrotron radiation is (D. H. Tombaoulion and P. L. Hartman, Phys. Rev. vol. 102, pp. 1423-46, 1956.): Δ E ( K e V ) = 88.5 · ( E e ( G e V ) ) 4 R ( meters )
where ΔE(KeV) is the energy loss of the electron expressed in kiloelectron volts, E e (GeV) is the initial energy of the electron in gigaelectron volts and R(meters) is the radius of the magnetic storage ring in meters. For a 1 GeV electron in a 1 meter diameter ring, the energy loss would by 88.5 KeV or a relative change of 88.5×10 −6 . Although a change in energy on the order of 10 −4 is small, it can be sufficient to trap an electron in a magnetic field if its initial trajectory is close to that of a closed path within the magnetic ring. However, a 100 MeV electron would experience an energy loss of 8.85 eV or approximately on part in 10 7 . This results in an unacceptably small deviation of the injection path from a closed path in the magnetic ring. For 10 MeV electrons, even using a ring of 10 cm diameter, the energy loss is 8.85 meV or approximately one part in 10 9 . Thus, synchrotron radiation is a highly inefficient braking mechanism for the capture of 100 MeV or smaller energy electrons in a magnetic storage ring. Nakayama (U.S. Pat. No. 4,988,950) describes some of the difficulties of injecting a low energy electron beam. These include that the lifetime of a low energy (40 MeV) beam is typically several minutes, which is sufficient for use with a solid radiator target, but is not compatible with the long storage times needed to build up a the large current necessary for intense synchrotron sources. Note that Nakayama uses a pulsed deflection magnet for electron beam capture.
Prior Art—Gas Damping
Electron storage rings have been proposed using a gas, such as hydrogen, to focus electrons injected into a storage ring. In addition, a thin solid target is proposed as a means of enhancing the radiation production of this device. It has been recognized that the gas and thin solid target act to dampen the electron beam, and that this damping can increase the repetition rate for resonance injection. However, resonance injection, using a perturbator with a magnetic field that turns on and off in approximately 0.1 microseconds is still required. The use of a perturbator greatly increases the cost and complexity of the system. H. Yamada, U.S. Pat. No. 5,680,018.
Prior Art—Internal Injection/betatron
One means to capture such lower energy electrons in a storage ring is to inject them from a point inside the magnetic ring. An example of this is a betatron, where electrons are injected from a point inside the radial containment field. (D. W. Kerst, Phys. Rev. vol. 60, pp.47-53, 1941; R. Kollath Particle Accelerators (Pitman and Sons: London) 1967. However, the requirement to inject from an internal point limits the size of the injector and thus the maximum energy of injection. The typical injection energy for betatrons is around 50 KeV. The electrons are then accelerated to higher energies by magnetic induction in the betatron. However, the efficiency of injection into the magnetic ring at energies below 1 MeV is limited by space charge effects, limiting betatrons to average of 10 μA or less, much smaller than the current available from linear accelerators, which can be on the order of mA's. Indeed, typical betatron currents are 1 μA or less. In addition, the injection into a betatron must be timed with the accelerating field, and a large time-varying magnetic field must be provided for acceleration. These requirements limit the operating frequency of a betatron to approximately 1 KHz or less. Continuous injection is not possible.
SUMMARY OF THE INVENTION
The invention uses a solid target in a magnetic storage ring to slow, and capture in a magnetic field, particles injected from a point external to the magnetic field. No magnetic pulsing system is required, and electron energies from several KeV to GeV can be captured. The braking target can also be used to produce radiation. Since the particle beam is in a storage ring, it can pass multiple times through the target, providing much greater efficiency than a single pass radiator system. As an example, a 30 MeV electron directed into a magnetic ring and passing through a 34 micron beryllium foil within this ring would lose 10 KeV of energy or 0.03%. This loss effectively increases the strength of the magnetic field by 0.03%, thus creating the same effect as a kicker magnet but in the 113 femptoseconds that it takes the electron to traverse the foil. The effective increase in magnetic acceleration allows the field of the magnetic ring to hold the electron in a closed orbit. Since only a small fraction of the electron's energy is lost on each pass through the target, it can potentially pass through the target hundreds of times.
ADVANTAGES
External injection permits many more electrons (or other charged particles) to be captured in the storage ring than is possible using internal injection, greatly increasing the intensity of radiation from the radiator target over that offered by betatrons or other internal injection methods.
The current method of external injection is passive, allowing for continual injection, rather than a limited duty cycle of pulses as for methods based on varying magnetic fields.
The current method of external injection is passive, eliminating the need for a high-speed pulsed magnet, thus reducing system cost and size and increasing reliability.
The current apparatus and method can use storage rings much smaller than one meter in diameter since particles are captured within femptoseconds. In principle, the only limit on size is the ability to construct a magnet and radiation target of a given size.
The current apparatus and method can capture electrons with energies below 100 MeV, which is very difficult using traditional methods based on synchrotron radiation, both because the synchrotron damping is insufficient and because long electron beam lifetimes (many minutes) are required to convert the electron's energy to synchrotron radiation. Lower energy electron beams are inherently less stable; however, the present invention extracts the electron's energy into radiation in a fraction of a second.
The charged particle beam can pass through the radiator multiple times, greatly increasing the radiation efficiency over that from a single pass from the injector, such as could be achieved using a linear accelerator and radiation target without the storage ring.
Much lower electron beam energies can be used. Solid targets are more efficient x-ray generators per electron than synchrotron radiation, especially at low electron beam energies. This greatly decreased the size and cost of the apparatus for a given radiation energy over that for synchrotrons or other storage ring radiation sources.
Advanced methods of radiation generation can also be used, including transition radiation, parametric radiation, Cerenkov, bremsstrahlung, coherent bremsstrahlung.
Thin braking targets can be combined with thick bremsstrahlung radiating targets to produce an intense microspot bremsstrahlung source with radiation source dimensions of 100 microns square or even smaller.
Vacuum requirements are much lower than for synchrotrons or other storage rings, since the charged particles need only pass through the target hundreds or thousands of times to convert their energy to radiation. A vacuum of 106 Torr is required rather than 10 −10 Torr as for most storage rings.
The energy of the resulting radiation can be controlled by the type of radiator target used, so that the radiation energy can be chosen independent of the electron energy.
DRAWING FIGURES
FIG. 1 shows the structure and main elements of a magnetic containment system using a beam of externally injected electrons, an embodiment of the present invention.
FIG. 2A shows the radial acceleration for a charged particle in a magnetic storage ring.
FIG. 2B shows the radial potential for a charged particle in a magnetic storage ring.
FIG. 3 shows the structure of a compound damping and radiating target for use in static magnetic storage rings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows external injection of an electron into a magnetic storage ring 10 . The magnetic storage ring is formed by a static annular magnetic field between two blocks of magnetic material 12 and 14 . The magnetic field acts to turn an electron of greater than 100 KeV energy launched from a source, 16 , external to the effective magnetic field of the ring. The path of the electron, 18 , forms a spiral around the axis of the magnetic ring and passes through a solid target, 20 . The magnetic field is constructed so that the electron will then spiral out from the center passing through the target multiple times. The electron path is contained in a vacuum to prevent undesired energy loss to the electron. A vacuum of approximately 10 −6 Torr is required for a ring 1 meter or less in diameter. The action of the electron passing through the target produces radiation 22 , typically x-ray or gamma radiation.
Operation
The capture process can be described using a radial magnetic potential in the following way. The electron (or any charged particle) will experience both Lorentz and centripetal forces as its path is bent by a magnetic field. The total force experienced by the electron is always perpendicular to its path (radial for a circular orbit). For this derivation we will assume circular symmetry, though the results can be generalized to any orbit geometry for the electrons. The radial force and acceleration are describe by: A radial = F eff m = v 2 r - evB ( r ) m
where F eff is the effective force on the electron (positive force is outward radially), A radial is the resulting radial acceleration, m is the electron mass, v the velocity of the electron, r the radius of the orbit, e the electron charge, and B(r) the magnetic field. The acceleration can be integrated to yield a radial potential U radial (r) that includes the effect of the electron mass and its changes.
The capture process can be better understood by looking at a sample plot of A radial and U radial (r). FIGS. 2A and B show A radial and U radial for a hypothetical static magnetic field. The difficulty with external injection in contrast to internal injection can be seen from these figures. If a particle is injected with minimal radial velocity into the magnetic ring at point A, internal to the magnetic field, it will not escape from the potential well formed by the centripetal and magnetic forces. That is, for any radial deviation from point A, F eff will act to return the particle to point A. As long as the radial energy of the particle is not sufficient to rise to point B, it will be captured. However, if a particle is injected into the magnetic field from an external point, that is from a point past the capture radius, B, the particle must have a negative radial velocity (towards the center) to climb to and pass point B in the potential. The particle must have a nonzero velocity when at point B since B is an equilibrium point. But given this condition, the particle will accelerate from point B through point A; it will then be slowed by F eff , until it comes to a stop on the left side wall at a point slightly higher than point B. The particle will then accelerate down the wall, pass through point A and pass through point B with a positive radial velocity, thus escaping the magnetic ring.
In order to capture the externally injected electron, either it must be slowed radially or the potential walls must be raised. The acceleration acting on the particle can be varied when the particle is at or near point A to increase the integral of the force between points A and B, that is, the difference in potential between points A and B. From the equation for A radial , it is clear that an increase in the magnetic field decreases A radial , thus increasing the potential difference between points A and B, which would make it possible to capture the particle. This has been generally the approach of the prior art for large diameter rings. However, for magnetic rings under 1 m in radius, the time available to make this change is generally on the order of 10 nanoseconds or less, which would require very fast time varying magnets, thereby being extremely expensive or even infeasible. It is the change in potential that captures the particle. For a particle with a relativistic energy (v≈c, the speed of light), the energy lost through radiation, such as synchrotron radiation, or through collisions will result in a decreased effective mass while the velocity remains approximately equal to the speed of light. The decreased mass lowers the centripetal force, making it easier to contain the particle. However, synchrotron radiation does not cause a significant energy loss per orbit for electrons below 100 MeV. Using a material target allows a significant change in A radial and thus U radial even for electron energies below 100 MeV. The decrease of the electron's mass due to deceleration in a material radiator target decreases the radial acceleration increasing the area under the A radial curve between points A and B, thus increasing the height of the potential well. Since substantial energy (hence mass) losses can be generated by interaction with a material target, particles of any energy can be captured by the placement of a material target placed at a radius less than that of point B. In contrast, the quadratic dependence of synchrotron radiation on the particle energy limits its use for low energy particles.
Note that the radial magnetic potential, U radial , must increase for small radii to repel the particle back toward the target from the center of the magnetic ring. This can be achieved by decreasing the strength of the magnetic field at the center of the ring.
The target used to slow the electron can also be used to generate radiation. Relativistic electrons, or other particles, travelling through a crystal or other material are known to generate radiation according to various radiation mechanisms. Such mechanisms include transition radiation, parametric radiation, Cerenkov radiation, bremsstrahlung and coherent bremsstrahlung. (M. A. Piestrup, J. O. Kephart, H. Park, R. K. Klein, R. H. Pantell, P. J. Ebert, M. J. Moran, B. A. Dahling, and B. L. Berman, “Measurement of transition radiation from medium-energy electrons,” Phys. Rev. A vol. 32, pp. 917-927, August 1985. M. A. Kumakhov, Phys. Lett. vol. 57, p. 17, 1976. R. W. Terhune and R. H. Pantell, Appl. Phys. Lett. Vol. 30, p.265, 1977.
A target designed to produce radiation from one of these mechanisms will produce radiation and damp the momentum of the externally injected electron, allowing it to be captured. As the electron cycles through the magnetic ring, each time it passes through the target it will generate radiation. (U.S. patent application Ser. No. 09/148,524. and M. Yu.Andreyashkin, V. V. Kaplin, M. A. Piestrup, S. R. Uglov, V. N. Zabaev, “Increased X-ray Production by Multiple Passes of Electrons trough Periodic and Crystalline Targets Mounted Inside a Synchrotron,” Appl. Phys. Letts. 72 pp. pp.1385-1387 (1998) and M. A. Piestrup, L. W. Lombardo, J. T. Cremer, G. A. Retzlaff, R. M. Silzer, D. M. Skopik and V. V. Kaplin, “Increased x-ray production efficiency from transition radiators utilizing a multiple-pass electron beam” The Review of Scientific Instruments 69, No. 6, pp. 2223-2229 (1998).) In this way, the amount of radiation from a non-circulating electron source, such as a linear accelerator, can be increased by 10 to 1000 or more times depending on the number of cycles it can make through the magnetic ring.
In one preferred embodiment, a typical electron injection energy would be about 4 MeV, and the injection angle would preferably be less than about 1 degree. Those skilled in the art will understand, however, that the angle generally needs to be somewhat tunable in order to optimize the injection. Those skilled in the art will also understand that larger angles of injection could also be used. However, in general, larger injection angles would make it more difficult to achieve the capture result. In this preferred embodiment, the two magnets provide a static annular magnetic field which is essentially zero outside a radius R of about 9.9 cm and inside a radius R of about 3.5 cm, with the field in between those two radii being given by B=B 0 /R, where B 0 =0.1708 γ tesla-cm. Also, a 4 micron beryllium foil would be an appropriate target. Those skilled in the art will also understand that it is useful to provide a moveable support for the target so that its position can be tuned to optimize the damping. Typically a range of about 1 cm is sufficient for the motion of the target. Those skilled in the art will also understand that the target may be cooled to avoid heat related problems, e.g. melting.
An alternative embodiment of the present invention can be used to produce hard x-rays and gamma rays from a small source area, or microspot. The thin radiating target 20 of FIG. 2 can be replaced by a compound target, shown in FIG. 3 . The compound target 30 consists of a larger area thin target 32 and a small area thick target 34 . The charged particles' direction, hereafter assumed to be an electron, is also shown 36 . The thin target is chosen so that it minimally slows electrons striking it. However, it must slow them sufficiently to allow capture, a condition that depends on the electron energy and parameters of the magnetic field. The area of the thin target should be large enough to provide efficient capture of externally injected electrons. The thick target is chosen to completely absorb electrons striking it. This implies that it will generally be made from high atomic number materials and will have a thickness from 100 microns to several millimeters depending on the electron energy. Electrons injected into the magnetic storage ring may strike either target. The number of times electrons will strike either target is approximately proportional to their area. Thus, if the area of the thin target is 100 times larger, it will be struck 100 times more often. However, since the electron only loses on the order of 0.01% of its energy on each pass through the thin target and 100% of its energy when striking the thick target, the intensity of radiation from the thick target will be 10-100 times more intense than that from the larger area thin target. This, in effect, creates a small spot hard x-ray source, which generates bremsstrahlung from a spot the size of the thick target. One practical design would be to have a 200 micron by 200 micron thick radiating target surrounded by a 4 square millimeter thin braking target. For a 4 MeV injected electron beam, an appropriate thick target would be Tungsten of about 100 microns in thickness, and an appropriate braking target would be beryllium of about 2-3 microns thick. Of course, many other materials may be used for either target.
CONCLUSION
The present invention provides a means for externally injecting an electron, or other charged particle, beam into a magnetic storage ring. Electron capture is affected by the damping of the electron's momentum when it strikes a solid target in the storage ring. This target serves the dual purpose of damping and producing radiation, though these functions could, in theory, be separated. The momentum damping caused by the target, decreases the mass of relativistic particles, thus increases the containing power of the magnetic field of the storage ring. Capture takes place when this extra magnetic containment force is sufficient to overcome the radial momentum of the charged particle as it approaches the edge of the containment field.
This method and the resulting apparatus can capture lower electron energies using smaller storage rings and over a greater duty cycle than is currently possible with other external injection technologies, such as those used for synchrotrons, including kicker magnets, synchrotron radiation damping, perturbators and resonance injection. In addition this invention provides a much greater captured beam current than is possible with betatrons and other internal injection accelerators. The electron beam in a storage ring can be passed through a thin target up to thousands of times, greatly increasing the radiation flux produced over that achievable from an electron source without the storage ring. This is particularly advantageous for the production of soft x-rays since the radiation production from a single pass is a small fraction of the electron's energy.
This invention could be used to construct radiation sources for industrial, scientific and medical uses including semiconductor lithography, medical imaging, x-ray diffraction, x-ray fluoroscopy, x-ray microscopy and high resolution non-destructive testing, amongst other applications. Since the size of the storage ring is only limited by the ratio of the magnetic field to the electron energy, extremely small devices are possible. | The present invention includes a magnetic storage ring into which electrons or other charged particles can be injected from a point external to the ring and still subscribe a path, after injection, contained within the magnetic storage ring. The magnetic storage ring consists of purely static (permanent) magnetic fields. The particles pass one or more times through a solid target that causes the high energy charged particles to emit radiation and damps the momentum of the particles, so that they cannot escape the magnetic field, allowing them to be captured therein. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to a granular defoamer and a method for preparation of the granular defoamer. Defoamers belong to fine chemical additives; therefore, the present invention belongs to the technical field of fine chemicals.
BACKGROUND OF THE INVENTION
[0002] Industrial cleaning agents are used in industrial cleaning process to remove filth and reduce oil-water surface tension. Cleaning agents contain a large quantity of surfactant. In the agitation process, the surfactant will be absorbed around the bubbles to stabilize the bubbles, and thereby produce a large quantity of foams. Such a phenomenon is prominent in industrial processes such as cleaning of beer bottles, cleaning of heat-exchange equipment, boilers, and heat exchange pipelines, cleaning of steel sheets, cleaning of machines, and cement and starch pasting, etc. The existence of foams will cause degraded productivity, waste of raw materials and products, prolonged reaction period, degraded product quality, and environment pollution, etc. Therefore, foam elimination is of great importance. In industrial processes, defoamers are often added to eliminate foams.
[0003] Defoamers are mainly categorized into organic silicon defoamers and non-organic silicon defoamers by the active component. Most defoamers in heavy-duty powder detergent and heavy-duty liquid detergent products for drum-type washing machines are organic silicon defoamers, and siloxane defoamers are deemed as very effective in that application, because they can be used in low dosage and are not affected by water hardness; in contrast, conventional defoamer compositions, such as soaps, have certain requirements for water hardness. Most of best-selling organic silicon defoamers in the market are liquid products, and have drawbacks such as poor compatibility with the products to be defoamed and narrow applicability, etc., owing to the fact that they can not be added to solid products because they have high water content. In the cleaning industry, solid defoamers have their unique advantages.
[0004] Many research and development efforts have been made for solid defoamers: patent documents EP0496510A1 and EP1070526A2 introduce fatty acid, fatty alcohol, alkyl phosphoric acid, and nonpolar hydrocarbon additives with melting point 30˜100° C. as antifoaming ingredients; though these ingredients can form intermittent wax coating to encapsulate the active substances, they can not completely solve the problem of uneven distribution of the defoaming active substances; in EP1075863 and WO2005058454, the defoaming performance is enhanced by introducing a hydrophobic organic liquid; in WO2005058455, the foam elimination and suppression performance is enhanced by introducing a nonpolar additive with melting point 35˜100° C. and a non-silicon organic liquid; in EP1118655A1, the foam suppression performance of a silicone foam-controlling component is improved by adding oleyl alcohol; EP1075864A2 and WO2008043512 mainly introduce the organic silicon active substance, and do not put forth any restriction on the particle size of the carrier, such as sodium carbonate, sodium sulfate, sodium tripolyphosphate, and sodium borate. The particle can not absorb enough active substances and can not attain the expected defoaming effect if the particle size is too small; in addition, these patent documents do not describe how to make the active substances more easily to disperse and evenly agglomerate to the carrier; EP0636685A2, EP0718018A2, EP0995473A1, EP329842, U.S. Pat. No. 5,861,368, U.S. Pat. No. 6,165,968, WO 9716519A1, and U.S. Pat. No. 6,610,752 describe defoamers with zeolite as the carrier; viewed from the composition and structure, zeolite is in a porous “cage-type” structure, which can easily “trap” the defoaming active substances and will not give full play to the defoaming effect of the active substance. A large number of literatures have shown: the activity of defoamers with zeolite as the carrier will decay as the storage time increases. There are many counter measures against that problem: for example, encapsulate the active substances with protective film; introduce silicone polyether, so that the silicone polyether is absorbed to the carrier in advance to block up the porous structure of zeolite, or add wax substance that can form intermittent coating, etc.; however, all these measures can not completely solve the decay problem of the defoamers. CN1177630A describes a solid carrier based granular defoamer that can produce an alkaline pH when it is exposed to water, but the defoamer tends to absorb moisture when it is laid aside; EP142910 discloses the application of a water soluble or water dispersible organic carrier, which contains a first organic carrier component with melting point at 38˜90° C. and a second carrier component selected from oxyethylated non-ionic surfactant that achieves hydrophile-lipophile balance at 9.5˜13.5° C. and has melting point at 5˜36° C.; U.S. Pat. No. 4,894,177 describes a granular defoamer with modified cellulose as the carrier; US2003211961 describes a defoamer with the polymer, copolymer, or mixture of one or more acrylic resins as the carrier. In addition, the defoaming performance of all above defoamers has to be improved further.
[0005] Most of the solid defoamers described in above patent documents utilize carrier selection or utilize a combination of silicone grease and other auxiliary agents to attain the balance of foam elimination and suppression. However, these defoamers can not achieve ideal foam control effect in the early stage and late stage of washing, and can not ensure defoaming stability of the product, because it is difficult to achieve even distribution of the silicone grease in carrier if the silicone grease is not emulsified and dispersed in advance. It is a great concern of many specialists and scholars on how to achieve high foam control performance in the early stage and late stage of washing while maintaining defoaming stability of the product.
[0006] The inventor utilizes silicone emulsion to replace silicone grease and controls the silicone emulsion to agglomerate to the carrier in steps, forming two silicone grease adsorption “layers”; in that way, the problems of extremely high concentration gradient of silicone grease and uneven distribution of silicone grease resulted from agglomeration in one operation are alleviated, and enough defoaming component exists in the exterior part and interior part of the defoamer particles, achieving a slow release effect; hence, the foam elimination and suppression performance and stability of the product are improved. The prepared solid granular defoamer attains a preferable foam elimination and suppression effect in cleaning processes, such as cleaning of beer bottles, cleaning of heat-exchange equipment, boilers, and heat exchange pipelines, cleaning of steel sheets, cleaning of machines, cement and starch pasting, and powder detergent industry.
SUMMARY OF THE INVENTION
[0007] Technical problem to be solved: The present invention provides a method for preparation of solid granular defoamer, with which a solid granular defoamer with improved foam elimination and suppression performance and improved stability can be obtained. The defoamer described in the present invention can maintain favorable foam elimination and suppression effect in the early stage and late stage of washing process, when it is used in powder detergents. In addition, the product has superior defoaming stability.
Technical Solution
[0008] The present invention provides a granular defoamer and a method for preparation of the granular defoamer: two silicone grease adsorption “layers” are formed by controlling silicone emulsion to agglomerate to the carrier in steps; thus, the problems of extremely high concentration gradient of active substances and uneven distribution of silicone grease resulted from agglomeration in one operation are alleviated, and the foam elimination and suppression performance and stability of the product are improved.
[0009] The granular defoamer described in the present invention comprises the following components:
[0010] A. Carrier
[0011] The carrier is selected from sulfate, carbonate, phosphate, polyphosphate, starch, cellulose or aluminosilicate, which are solid at room temperature; preferably, the carrier is starch, or sulfate or carbonate with particle size greater than 300-mesh; sulfate and carbonate with particle size smaller than 300-mesh are not recommended for the carrier in the present invention, owing to their low adsorption force. They can be used separately or in mixture, dosed at 55˜75% of total mass of the granular defoamer.
[0012] The carrier in the present invention is added in two parts, which are denoted as A1 and A2 respectively; the mass ratio of A1 to A2 is 4:1-15:1.
[0013] B. Silicone Emulsion
[0014] The silicone emulsion is prepared from silicone grease, silicone polyether, emulsifying agent, and deionized water; the method for preparation can be found in existing professional literatures. The silicone emulsion is dosed at 15˜35% of total mass of the granular defoamer.
[0015] (1) Silicone grease: obtained from reaction of organopolysiloxane, silicone resin, silicon dioxide, hydrophobic treatment agent, and basic catalyst. The method for preparation can be found in existing professional literatures. The silicone grease is dosed at 20%˜40% of total mass of the silicone emulsion.
[0016] (2) Silicone polyether: prepared from additive reaction of hydrogen-containing polysiloxane and unsaturated polyether under the action of an acidic catalyst; the method for preparation can be found in existing professional literatures. The silicone polyether has 10˜30,000 mPa·s kinetic viscosity at 25° C., preferably has 60˜5,000 mPa·s at 25° C. It is dosed at 5%˜10.5% of total mass of the silicone emulsion.
[0017] (3) Emulsifying agent: a non-ionic surfactant. It is dosed at 2%˜7.5% of total mass of the silicone emulsion.
[0018] (4) Deionized water: dosed at 3%˜80% of total mass of the silicone emulsion.
[0019] The silicone emulsion is added in two parts, which are denoted as B1 and B2 respectively; the mass ratio of B1 to B2 is 4:1˜10:1.
[0020] C. Texturing Agent
[0021] Commonly used texturing agents include: (1) acrylic polymer, including polyacrylic acid and sodium polyacrylate, and copolymer of maleic acid and acylic acid; (2) cellulose ether, which refers to water soluble or water swellable cellulose ether, including sodium carboxymethylcellulose; (3) citric acid or citrate, including sodium citrate and potassium citrate; (4) polyvinylpyrrolidone.
[0022] Such texturing agents can be used separately, or used in mixture at any mix ratio. The texturing agent is dosed at 3˜10% of total mass of the granular defoamer.
[0023] D. Solvent
[0024] The evaporation of solvent will create cavities in the solid particles, and thereby increasing the specific surface area of the solid particles. The solvents comprise alcohol and water, such as methanol, ethanol, or isopropanol, preferably ethanol and water. They can be used separately, or used in mixture at any mix ratio. The solvent is dosed at 2˜10% of total mass of the granular defoamer.
[0025] The method for preparation of granular defoamer comprises the following steps:
[0026] (1) adding carrier A1 into a mixer, and then adding silicone emulsion B1 into the mixer and stirring uniformly;
[0027] (2) adding carrier component A2 into the mixture obtained in step (1), and stirring uniformly;
[0028] (3) adding silicone emulsion B2 into the mixture obtained in step (2) and after uniformly stirring, adding the texturing agent and stirring uniformly, and adding the solvent and stirring uniformly;
[0029] (4) pelleting and drying the mixture obtained in step (3) and the obtained mixture is the prepared granular defoamer.
[0030] Beneficial effects: in the present invention, since the silicone grease is emulsified into silicone emulsion in advance, the problems of difficulty in dispersion of silicone grease and uneven distribution after agglomeration to the carrier are alleviated, and the quality homogeneity of defoamer is ensured; moreover, since the silicone emulsion is added into the carrier in steps, the problem of extremely high concentration gradient of silicone grease resulted from agglomeration in one operation is solved, and foams can be eliminated fully in the early stage and the active substances can be released for prolonged time in the entire process; therefore, the foam elimination and suppression is complete in the entire washing process, and thereby the continuous defoaming stability of the product is improved.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0031] The defoaming active substances obtained with the preparation method described in Example 1 and Example 2 in ZL200610040821.3 are high-viscosity silicone grease mixture G1 and high-viscosity silicone grease mixture G2 respectively.
[0032] Prepare silicone polyether E 1 , E 2 , E 3 , E 4 , E 5 and E 6 ; the structural formula is:
[0000]
[0033] Where, the values of R, R 1 , r, s, e, f and i are shown in Table 1:
[0000]
TABLE 1
Silicone Polyether E 1 , E 2 , E 3 , E 4 , E 5 and E 6
Silicone polyether
E 1
E 2
E 3
E 4
E 5
E 6
R
—CH 3
—C 2 H 5
—CH 3
—C 3 H 7
—C 2 H 5
—CH 3
R1
—H
—CH 3
—C 2 H 5
—CH 3
—C 2 H 5
—H
r
2
152
84
195
22
10
s
3
45
26
38
24
5
e
48
22
2
15
25
44
f
30
24
46
3
4
28
t
3
4
2
6
3
4
[0034] 1. Preparation of Silicone Emulsion
[0035] (1) Preparation of Silicone Emulsion S1:
[0036] At room temperature, mix 20 parts of G1, 1.5 parts of Peregal O-25, 0.5 parts of sorbitan monooleate, 3 parts of silicone polyether E 2 , and 3 parts of silicone polyether E 1 and heat up to 70° C. while stirring, and let them to emulsify and mix completely for 35 min.; then, keep the temperature of the system at 70° C., add water slowly, and increase the stirring rate to invert the water-in-oil emulsion to oil-in-water emulsion, continue adding water to the required mass concentration (50%). Emulsify further the mixture in a colloidal mill, to obtain the required silicone emulsion S1.
[0037] (2) Preparation of Silicone Emulsion S2:
[0038] At room temperature, mix 30 parts of G2, 4.5 parts of Peregal O-15, 3 parts of sorbitan monooleate, 2.5 parts of silicone polyether E 1 , and 4 parts of silicone polyether E 3 and heat up to 80° C. while stirring, and let them to emulsify and mix completely for 40 min at 80° C.; then, keep the temperature of the system, add water slowly, and increase the stirring rate to invert the water-in-oil emulsion to oil-in-water emulsion, continue adding water to the required mass concentration (60%). Emulsify further the mixture in a colloidal mill, to obtain the required silicone emulsion S2.
[0039] (3) Preparation of Silicone Emulsion S3:
[0040] At room temperature, mix 20 parts of G2, 20 parts of G1, 4.5 parts of Peregal O-15, 3 parts of sorbitan monooleate, 4.5 parts of silicone polyether E 3 , and 6 parts of silicone polyether E 4 and heat up to 80° C. while stirring, and let them to mix completely for 40 min at 80° C.; then, keep the temperature of the system, add water slowly, and increase the stirring rate to invert the water-in-oil emulsion to oil-in-water emulsion, continue adding water to the required mass concentration (70%). Emulsify further the mixture in a colloidal mill, to obtain the required silicone emulsion S3.
[0041] (4) Preparation of Silicone Emulsion S4:
[0042] At room temperature, mix 20 parts of G2, 20 parts of G1, 4.5 parts of Peregal O-15, 3 parts of oleic acid polyoxyethylene(6) ether, 4.5 parts of silicone polyether E 5 , and 6 parts of silicone polyether E 6 and heat up to 80° C. while stirring, and let them to mix completely for 40 min at 80° C.; then, keep the temperature of the system, add water slowly, and increase the stirring rate to invert the water-in-oil emulsion to oil-in-water emulsion, continue adding water to the required mass concentration (60%). Emulsify further the mixture in a colloidal mill, to obtain the required silicone emulsion S4.
[0043] (5) Preparation of Silicone Emulsion S5:
[0044] At room temperature, mix 20 parts of G2, 20 parts of G1, 4.5 parts of Peregal O-20, 3 parts of sorbitan monostearate, 4.5 parts of silicone polyether E 1 , and 6 parts of silicone polyether E 5 and heat up to 80° C. while stirring, and let them to mix completely for 40 min at 80° C.; then, keep the temperature of the system, add water slowly, and increase the stirring rate to invert the water-in-oil emulsion to oil-in-water emulsion, continue adding water to the required mass concentration (50%). Emulsify further the mixture in a colloidal mill, to obtain the required silicone emulsion S5.
[0045] 2. Preparation of Solid Granular Defoamer
Embodiment 1
[0046] Add 70 g starch into a mixer, add 12.5 g silicone emulsion S2 into the mixer, and stir uniformly; then, add 5 g starch and stir uniformly, and add 2.5 g silicone emulsion S4 and stir uniformly. Next, add 2 g sodium carboxymethylcellulose and 3 g polyacrylic acid and continue stirring; after stirring uniformly, add 5 g absolute ethyl alcohol and stir uniformly, and then pellet and dry the obtained mixture, so as to obtain an embodiment 1 of granular defoamer.
Embodiment 2
[0047] Add 60 g sodium sulfate (800-mesh) into a mixer, add 16.5 g silicone emulsion S2 into the mixer, and stir uniformly; then, add 9 g sodium sulfate (800-mesh) and stir uniformly, and add 3.5 g silicone emulsion S5 and stir uniformly. Next, add 2 g sodium citrate and 3 g copolymer of maleic acid and acrylic acid and continue stirring ; after stir uniformly, add 3 g absolute ethyl alcohol and 3 g deionized water, and stir uniformly; then pellet and dry the obtained mixture, so as to obtain an embodiment 2 of granular defoamer.
Embodiment 3
[0048] Add 50 g sodium sulfate (1250-mesh) into a mixer, add 29 g silicone emulsion S3 into the mixer, and stir uniformly; then, add 9 g sodium carbonate (300-mesh) and stir uniformly, and add 2 g silicone emulsion S1 and 4 g silicone emulsion S2, and stir uniformly. Next, add 3 g polyacrylic acid and continue stirring; after stir uniformly, add 3 g deionized water and stir uniformly; then pellet and dry the obtained mixture, so as to obtain an embodiment 3 of granular defoamer.
Embodiment 4
[0049] Add 63 g sodium sulfate (300-mesh) into a mixer, add 14 g silicone emulsion S1 into the mixer, and stir uniformly; then, add 10 g cationic starch and stir uniformly, and add 3 g silicone emulsion S2 and stir uniformly. Next, add 8 g polyacrylic acid and continue stirring; after stir uniformly, add 2 g deionized water and stir uniformly; then pellet and dry the obtained mixture, so as to obtain an embodiment 4 of granular defoamer.
Embodiment 5
[0050] Add 65 g sodium sulfate (800-mesh) into a mixer, add 17 g silicone emulsion S1 into the mixer, and stir uniformly; then, add 7 g cationic starch and stir uniformly, and add 1.5 g silicone emulsion S3 and 1.5 g silicone emulsion S4, and stir uniformly. Next, add 3 g sodium carboxymethylcellulose and 3 g polymer of maleic acid and acrylic acid and continue stirring; after stir uniformly, add 2 g absolute ethyl alcohol and stir uniformly, and then pellet and dry the obtained mixture, so as to obtain an embodiment 5 of granular defoamer.
Embodiment 6
[0051] Add 60 g sodium sulfate (1250-mesh) into a mixer, add 18 g silicone emulsion S2 into the mixer, and stir uniformly; then, add 5 g sodium sulfate (1250-mesh) and stir uniformly, and add 2 g silicone emulsion S3 and stir uniformly. Next, add 3 g sodium carboxymethylcellulose, 3 g sodium citrate, and 4 g polyacrylic acid, and continue stirring; after stir uniformly, add 2 g absolute ethyl alcohol and 3 g deionized water, and stir uniformly; then pellet and dry the obtained mixture, so as to obtain an embodiment 6 of granular defoamer.
Embodiment 7
[0052] Add 50 g sodium sulfate (1250-mesh) into a mixer, add 12.6 g silicone emulsion S1 and 12 g silicone emulsion S2 into the mixer, and stir uniformly; then, add 5 g sodium carbonate (1250-mesh) and stir uniformly, and add 2 g silicone emulsion S4 and 3.4 g silicone emulsion S5, and stir uniformly. Next, add 2 g sodium carboxymethylcellulose, 5 g sodium citrate, and 3 g polyacrylic acid and continue stirring; after stir uniformly, add 5 g absolute ethyl alcohol and stir uniformly, and then pellet and dry the obtained mixture, so as to obtain an embodiment 7 of granular defoamer.
Embodiment 8
[0053] Add 55 g sodium carbonate (800-mesh) into a mixer, add 13 g silicone emulsion S2 into the mixer, and stir uniformly; then, add 10 g cationic starch and stir uniformly, and add 2 g silicone emulsion S5 and stir uniformly. Next, add 10 g polymer of maleic acid and acrylic acid and continue stirring; after stir uniformly, add 10 g deionized water and stir uniformly; then pellet and dry the obtained mixture, so as to obtain an embodiment 8 of granular defoamer.
Embodiment 9
[0054] Add 47 g sodium carbonate (800-mesh) into a mixer, add 10 g silicone emulsion S1 and 12 g silicone emulsion S2 into the mixer, and stir uniformly; then, add 10 g cationic starch and stir uniformly, and add 3 g silicone emulsion S3 and stir uniformly. Next, add 5 g sodium carboxymethylcellulose, 2 g sodium citrate, and 3 g polyacrylic acid, and continue stirring; after stir uniformly, add 8 g deionized water and stir uniformly, and then pellet and dry the obtained mixture, so as to obtain an embodiment 9 of granular defoamer.
Embodiment 10
[0055] Add 50 g sodium carbonate (800-mesh) into a mixer, add 12 g silicone emulsion S1 and 18 g silicone emulsion S2 into the mixer, and stir uniformly; then, add 5 g sodium carbonate (800-mesh) and stir uniformly, and add 5 g silicone emulsion S3, and stir uniformly. Next, add 4 g polyacrylic acid and continue stirring,; after stir uniformly, add 6 g deionized water and stir uniformly; then pellet and dry the obtained mixture, so as to obtain an embodiment 10 of granular defoamer.
Embodiment 11
[0056] Add 60 g sodium carbonate (1250-mesh) into a mixer, add 13 g silicone emulsion S2 into the mixer, and stir uniformly; then, add 5 g sodium carbonate (1250-mesh) and stir uniformly, and add 2 g silicone emulsion S3 and stir uniformly. Next, add 3 g sodium carboxymethylcellulose, 3 g sodium citrate, and 1 g polymer of maleic acid and acrylic acid, and continue stirring; after stir uniformly, add 5 g deionized water and 5 g absolute ethyl alcohol, and stir uniformly; then pellet and dry the obtained mixture, so as to obtain an embodiment 11 of granular defoamer.
Comparative Embodiment 1
[0057] Add 75 g starch into a mixer, add 10 g high-viscosity silicone grease mixture G1 and 5 g high-viscosity silicone grease mixture G2, and mix uniformly; then, add 2 g sodium carboxymethylcellulose and 3 g polyacrylic acid. After stirring uniformly, add 5 g absolute ethyl alcohol, and stir uniformly; pellet and dry the obtained mixture, so as to obtain a comparative embodiment 1 of granular defoamer.
Comparative Embodiment 2
[0058] Add 25 g starch, 25 g sodium sulfate (1250-mesh), and 25 g sodium carbonate (800-mesh) into a mixer, add 5 g high-viscosity silicone grease mixture G1 and 10 g high-viscosity silicone grease mixture G2, and mix uniformly; then, add 2 g sodium carboxymethylcellulose and 3 g polyacrylic acid. After stirring uniformly, add 3 g absolute ethyl alcohol and 2 g deionized water, and stir uniformly; pellet and dry the obtained mixture, so as to obtain a comparative embodiment 2 of granular defoamer.
[0059] 3. Test of Foam Elimination and Suppression Performance
[0060] Test the embodiments of granular defoamer, comparative embodiments of granular defoamer, and samples of a foreign solid defoamer, with the following method.
[0061] (1) Test in Washing Machine
[0062] Testing method: add 50 g commercially available powder detergent and 0.3 g solid granular defoamer into a drum-type washing machine with 6 kg capacity, and test through the standard washing procedures. There are 5 measuring settings on the door of the washing machine. These settings indicate 0, 25%, 50%, 75%, and 100% of the door height, and are denoted as “0”, “1”, “2”, “3”, and “4” respectively. Setting “0” is the start point, and indicates “no foam”, while mark “4” indicates “full foam”. Record the foam height once every 5 min when the washing machine stops. A higher value indicates the foam height in the washing machine is higher and the foam suppression performance is poorer; within the same duration, a lower foam height indicates the foam suppression performance of the product is better. The test result is as follows:
[0000]
TABLE 3
Washing Machine Test Result
Time (min)
No.
0
5
10
15
20
25
30
35
40
Embodi-
M
0
0
<1
<2
≦2
<2
<3
>3
4
ment 1
N
0
0
<1
<2
>2
>2
>3
4
Embodi-
M
0
0
<1
<1
>1
<2
>2
<3
<3
ment 2
N
0
0
1
>1
>1
≦2
>2
>3
>3
Embodi-
M
0
0
<1
<1
<2
≦2
>2
2
<3
ment 3
N
0
0
>1
<1
≦2
>2
>3
3
>3
Embodi-
M
0
0
<1
≦2
<2
<3
>3
>3
4
ment 4
N
0
0
>1
>1
>2
>3
>3
4
Embodi-
M
0
0
<1
≦1
<2
<3
>3
>3
4
ment 5
N
0
0
<1
1
>2
<3
>3
4
Embodi-
M
0
0
<1
<1
<2
<2
>2
<3
≦3
ment 6
N
0
0
<1
<2
<2
<3
<3
≦3
4
Embodi-
M
0
0
<1
<1
<1
<2
2
<3
<3
ment 7
N
0
0
<1
<1
<2
≦2
2
<3
≦3
Embodi-
M
0
0
<1
≦2
<2
<2
>3
>3
>3
ment 8
N
0
0
1
≦2
<2
<3
>3
3
4
Embodi-
M
0
0
<1
1
<2
<2
2
<3
<3
ment 9
N
0
0
<1
1
<2
<3
3
>3
3
Embodi-
M
0
0
<1
<1
>1
<2
<2
<3
<3
ment 10
N
0
0
<1
<1
≦2
≦2
≦2
<3
≦3
Embodi-
M
0
0
<1
<2
2
<2
<3
>3
>3
ment 11
N
0
0
<1
2
>2
>2
>3
>3
4
Compar-
M
0
<2
<2
<3
>3
<3
>3
4
ative
N
0
<2
2
<3
>3
>3
4
embodi-
ment 1
Compar-
M
0
1
<2
<3
<3
<3
>3
4
ative
N
0
1
2
<3
<3
>3
4
embodi-
ment 2
Foreign
M
0
<2
>2
<3
>3
4
sample
N
0
2
3
4
Note:
In the above table, “M” indicates test in real time; “N” indicates the sample is tested after it is held at 40° C. for four weeks.
[0063] (2) Horizontal Circular Bubbling Method:
[0064] Testing method: four measuring settings 0, 1, 2, and 3 are marked out on the glass test mirror of a horizontal circular bubbling instrument (produced by Nanjing Sixin Scientific-Technological Application Research Institute Co., Ltd.). Setting “0” is the start point, and indicates “no foam”, while setting “3” indicates “full foam”. Add 14 kg of 0.3% water solution of sodium dodecyl benzene sulfonate (pH is 13) into the horizontal circular bubbling instrument, switch on the temperature control switch, heat up the foaming liquid to test temperature of 80° C., start the air pump and wait for the foams to rise to a specific height (the time required for the foams to rise to the height is the blank time), and then add 0.5 g defoamer into the liquid; record the change of foam height with time. The longer the time required for the foams to rise to the same height is, the higher the foam suppression performance is. The test result is shown in Table 4:
[0000]
TABLE 4
Test Result in Horizontal Circular Bubbling Instrument
Foam Height
Blank
0
1
2
3
Foam
Embodiment 1
3′03″
2′40″
6′24″
28′30″
32′26″
suppression
Embodiment 2
3′07″
2′25″
6′37″
26′54″
34′36″
time
Embodiment 3
3′09″
2′20″
5′58″
25′21″
34′46″
Embodiment 4
3′06″
2′42″
5′30″
22′21″
33′40″
Embodiment 5
3′07″
2′33″
6′30″
23′21″
30′40″
Embodiment 6
3′03″
2′27″
4′30″
25′21″
35′45″
Embodiment 7
3′06″
2′29″
6′01″
24′23″
36′43″
Embodiment 8
3′05″
2′25″
6′04″
28′32″
32′40″
Embodiment 9
3′04″
2′15″
6′42″
29′30″
34′06″
Embodiment 10
3′03″
2′20″
6′50″
30′23″
38′43″
Embodiment 11
3′06″
2′35″
5′25″
25′21″
30′10″
Comparative
3′09″
1′40″
5′40″
15′01″
17′46″
embodiment 1
Comparative
3′05″
1′45″
4′40″
14′07″
18′23″
embodiment 2
Foreign sample
3′07″
1′13″
4′18″
9′45″
13′32″
[0065] It is seen from above test: the granular defoamer prepared by controlling the silicone emulsion to agglomerate to the carrier in steps is homogeneous and has stable defoaming performance. It can achieve satisfactory defoaming effect in the early stage and prolonged release of the active substances in the entire process at a low dosage, and ensure satisfactory foam elimination and suppression in the entire washing process. Moreover, after it is held for four weeks at 40° C., its foam elimination and suppression performance is not changed much; in other words, it has preferable anti-decay characteristic. | A process for preparing a particle defoamer. The particle defoamer of 55%-75% of a carrier, 15%-35% of a silicone emulsion, 3%-10% of a texturing agent and 2%-10% of a solvent, based on the total weight of the particle defoamer; the process for preparing the particle defoamer is: (1)first adding a carrier A1 into a mixer, and then adding thereto a silicone emulsion B1, and stirring uniformly; (2)adding a carrier component A2 to the mixture obtained in (1), and stirring uniformly; (3)adding a silicone emulsion B2 to the mixture obtained in (2), and, after uniformly stirring, adding the solvent thereto and stirring uniformly; and (4)pelleting and drying by baking the mixture obtained in(3), so as to produce the product. | 2 |
CROSS REFERENCE
This is a Continuation-in-Part of application Ser. No. 10/017,097 filed Dec. 14, 2001, now U.S. Pat. No. 6,702,024, and entitled Dual Energized Hydroseal.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present seal assembly will function when pressured acts on it from two different directions. It is therefore sometimes referred to as a bi-directional seal or a dual energized hydroseal. The present invention can be used in a variety of different types of valves where a dual energized seal assembly is needed, as well as in cases where single-direction control is necessary.
2. Background of the Invention
The dual energized hydroseal includes a seal spool, two O-rings and two opposing seal cups. This bi-directional seal assembly can be used in a dirty fluid valve and a variety of other applications where a bi-directional seal assembly is needed, as well as in cases where a single direction seal assembly is necessary. For purposes of example, the dual energized hydroseal will be described in a dirty fluid valve, which is a type of cartridge valve frequently used in downhole tools. A plurality of dirty fluid valves are positioned in a downhole tool that is used for sampling wellbore fluids. A plurality of empty sample collection bottles are located in the downhole tool. When the tool is inserted in the wellbore, all of the dirty fluid valves are in the closed position as shown in FIG. 1 . When the downhole tool reaches a depth that needs to be sampled, a pilot valve is pulsed, causing the seal carrier to slide the dual energized hydroseal assembly along opposing seal plates and open the supply port, as shown in FIG. 2 . This allows wellbore fluids to enter the supply port of the dirty fluid valve and move through the longitudinal passageway of the valve and out the function port to a sample collection bottle. A plurality of sample collection bottles are often included in a single tool so that the wellbore may be sampled at different depths.
External pressures in a wellbore often exceed 20,000 psi absolute. After a sample has been collected, a pilot valve is pulsed, causing the seal carrier to move back to the close position as shown in FIG. 1 . The pressure inside the sample collection bottle is the same as the pressure in the wellbore at the collection depth. As the downhole tool is brought back to the surface, external pressure drops to standard atmospheric pressure, but the pressure inside the sample collection bottle remains at wellbore pressure, which may be in excess of 20,000 psi absolute.
The present seal assembly will function when pressure acts on it from two different directions. The present invention can be used in a variety of different types of valves. When the seal assembly of the present invention is constructed, the O-rings are squeezed into position and/or compressed approximately 40%. The squeeze of the O-rings causes them to act as springs urging the seal cups into contact with the opposing seal plates. By contrast, O-ring manufacturers such as Parker generally recommend that O-rings be squeezed axially approximately 20%–30% for static seal designs. The present invention is a static seal design. Other O-ring manufacturers, such as Apple, recommend that O-rings be squeezed axially for static seal in the range of approximately 25%–38%. Squeezing the O-rings more than recommended by most manufacturers improves the function in the present invention. The O-rings in the present invention perform a dual function as both the spring and the seal. They act as a spring to force the seal cups into contact with the opposing seal plates, at lower pressures and they act as a seal at higher pressures.
The present invention is rated to operate up to 30,000 psi and 350° F. Gilmore Valve Co., the assignee of the present invention, has previously produced a dirty fluid valve with a bi-directional seal that was rated to operate up to 20,000 psi absolute and 250° F. (see Gilmore Valve Co. drawing No. 25082, a copy of which is enclosed in the Informational Disclosure Statement which is filed concurrently herewith). The present invention uses two compressed O-rings to energize the bi-directional seal. The prior art dirty fluid valve from Gilmore Valve Co. used only one O-ring to energize a bi-directional seal. The prior art O-ring used by Gilmore Valve Co. in the dirty fluid valve shown in drawing No. 25082 was produced by Greene Tweed of Houston, Tex. from Viton® 90 durometer anti-explosive decompressive material. The present invention uses two O-rings produced from Buna-N 90 durometer material. Applicants have determined that a Parker No. 2-004 O-ring is suitable for use in the present invention. The Viton of the prior art is relatively stiff and the Buna-N of the present invention is more resilient. Buna-N has more of a memory and therefore works better than the Viton as a spring. The prior art Gilmore Valve Co. seal, described in drawing No. 25082, although it was bi-directional, loses sealing integrity at operational pressures in excess of 25,000 psi. The present invention is rated to operate up to 30,000 psi. The present invention functions at higher operational pressures because there are two O-rings instead of one, the O-ring material is different than the prior art, the mechanical and hydraulic sealing forces are improved, and the present seal design is less complicated.
U.S. Pat. No. 5,662,166 to Shammai, discloses an apparatus for maintaining at least downhole pressure of a fluid sample of upon retrieval from an earthbore. The Shammai device has a much more complex series of seal than the present invention. Further, the Shammi device does not have a dual-energized seal like the present invention.
U.S. Pat. No. 5,337,822 issued to Massie et al, discloses a wellfluid sampling tool. The Massie device maintains samples at the pressure at which they are obtained until they can be analyzed. The device does not, however, maintain this pressure by means of a dual-energized hydroseal. Rather, the device of Massey uses a hydraulically driven floating piston, powered by high-pressured gas such as nitrogen acting on another floating piston, to maintain sample pressure.
SUMMARY OF THE INVENTION
The seal assembly of the present invention uses two O-rings that are squeezed more than 38.5% causing them to act as springs urging the seal cups into sealing engagement at very low pressures with the seal plates and as seals at higher pressures. At higher pressure a seal is achieved because pressure on the rear of the seal cups forces them into sealing engagement with the opposing seal plates. The pressure forces act on the seal cups to achieve a tight metal to metal seal. The bi-directional seal assembly of the present invention is shown in a dirty fluid valve which is positioned in a downhole tool for sampling wellbore fluids. The seal assembly of the present invention can be used in a variety of other types of valves that require bi-directional seal assemblies and in other types of valves that only require a uni-directional seal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of a valve with the dual energized hydroseal. The valve is in the closed position in an unpressurized state.
FIG. 2 is a section view of the valve of FIG. 1 except the valve is in the open position and Fluid is shown flowing through the valve by the flow arrows.
FIG. 3 is a perspective view of the seal spool.
FIG. 4 is an enlarged section view of the seal spool and O-rings in a relaxed position.
FIG. 5 is a perspective view of one seal cup.
FIG. 6 is an enlarged cross sectional view of one seal cup.
FIG. 7 is an enlarged cross sectional view of the dual energized hydroseal exposed to supply pressure.
FIG. 8 is an enlarged cross sectional view of the dual energized hydroseal exposed to function pressure.
FIG. 9 is a sectional view of a valve with an alternative embodiment of the dual energized hydroseal. The valve is in the closed position in an unpressurized state.
FIG. 10 is an enlarged sectional view of a valve with an alternate embodiment of the dual energized hydroseal showing details of an alternate O-ring seal arrangement.
FIG. 11 is an enlarged sectional view of a portion of the valve showing the dual energized hydroseal exposed to supply pressure with the valve in a closed position.
FIG. 12 is an enlarged sectional view of the dual energized hydroseal showing the O-ring seals in an outward position as seen in FIG. 11 with the fluid pressure being applied on their inner perimeter.
FIG. 13 is an enlarged sectional view of a valve showing the O-ring seals compressed to an inner position with the fluid pressure being applied to the O-rings on their outer perimeter.
FIG. 14 is an enlarged perspective view of an outer seal back-up ring.
FIG. 15 is an enlarged perspective view of an inner seal back-up ring.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , the dirty fluid valve is generally identified by the numeral 10 . The valve 10 is a normally closed, two position, two-way valve. The valve 10 is sometimes referred to as a “cartridge” type valve, because it is often manufactured in the configuration of FIG. 1 and it is slipped into a valve chamber in the body of a downhole tool. The downhole tool typically have—or more dirty fluid valves, to test wellbore fluids at different well depths. Each valve 10 is in fluid communication with the wellbore and a sample collection bottle to hold wellbore fluids. The valve 10 is typically rated for operational pressures of up to 30,000 psi and temperatures of up to 350° F.
The valve 10 has a generally cylindrical body 12 which defines a longitudinal bore 14 which is sized and arranged to receive a seal carrier 16 . The seal carrier moves from a normally closed position shown in FIG. 1 to an open position shown in FIG. 2 .
The body 12 has threads 18 formed on one end to threadably engage the cap 20 . A cylinder cover 22 surrounds a portion of the body 12 . The cylinder cover 22 is rotationally held in place on the body by a set screw 24 and longitudinally in place by cap 20 .
The body 12 defines an open pilot port 26 which is in fluid communication with an open chamber 28 . The body 12 and the cylinder cover 22 define a close pilot port 30 which is in fluid communication with the close chamber 32 which is defined by the longitudinal bore 14 in body 12 , the cap 20 and the seal carries 16 . The open pilot port 26 is in fluid communication with a pilot open valve, not shown. The close pilot port 30 is in fluid communication with a pilot close valve, not shown. Both pilot valves are connected to a source of pressurized pilot fluid, not shown.
The seal carrier 16 has a transverse bore 34 sized and arrange to receive a bi-directional seal assembly generally identified by the numeral 36 . A transverse flow passageway 38 is also formed in the seal carrier 16 to facilitate fluid flow through the valve when it is in the open position.
A bore 40 is formed in the body 12 and is sized and arranged to receive the first seal plate 42 . A through bore 44 is formed in the seal plate 42 and is in fluid communication with a supply port 46 formed in the cylinder cover 22 .
A bore 48 is formed in the body 12 and is sized and arranged to receive the second seal plate 50 . A through bore 52 is formed in the seal plate 50 and is fluid communication with a supply port 54 formed in the cylinder cover 22 . For purposes of claim interpretation, the body 12 and the cylinder cover 22 may collectively be referred to as the body, although for manufacturing convenience, they are produced as two separate parts.
When the downhole tool is placed in the wellbore, pressures may reach 30,000 psi, depending on the depth of the well. Wellbore fluids exert this “supply pressure” as indicated by the arrow in FIG. 1 .
To shift the valve 10 from the closed position of FIG. 1 to the open position of FIG. 2 , the pilot open valve is actuated allowing pilot pressure to enter the open port 26 and the open chamber 28 . The force of the pressurized pilot fluid acting on the seal carrier 16 shifts it to the open position of FIG. 2 .
Referring to FIG. 2 , the valve 10 is shown in the open position. Wellbore fluids indicated by the flow arrows, pass through the open ports 46 and 54 of the cylinder cover 22 and the through bore 44 and 52 of seal plates 42 and 50 . The wellbore fluids then pass through the flow passageway 38 in the seal carrier 16 , the longitudinal bore 14 and out the function ports 56 and 58 , as indicated by the flow arrows, to the sample collection bottle, not shown. After the sample has been taken, the pilot close valve is actuated and pressurized pilot fluid enters the close port 30 and the close chamber 32 . The pilot fluid is typically pressurized in the range of 1,500 to 10,000 psi. The force of this pilot fluid on the seal carrier causes it to shift from the open position of FIG. 2 to the closed position of FIG. 1 . A spring 102 is positioned in the close chamber 32 . A typical spring rate for the valve 10 is 261 lb./in. The spring 102 urges the seal carrier 16 into the normally closed position of FIG. 1 .
An O-ring groove 104 is formed in the cap 20 and is sized and arranged to receive O-ring 106 which seals the cap 20 against the valve chamber in the downhole tool. A groove 108 is formed in the cylinder cover 22 and is sized and arranged to receive T-seal 110 which seals the cylinder cover 22 against the valve chamber in the downhole tool.
A groove 112 is formed in the body 12 and is sized and arranged to receive T-seal 114 . A groove 116 is formed in the body 12 and is sized and arranged to receive T-seal 118 . A groove 120 is formed in the body 12 and is sized and arranged to receive T-seal 122 . T-seals 114 and 118 seal and isolate the function port 56 against the valve chamber in the downhole tool, not shown. T-seals 118 and 122 seal and isolate the pilot open port against the valve chamber in the downhole tool, not shown.
A groove 124 is formed in the seal carrier 16 and is sized and received to receive an O-ring 126 and a lock-up ring 128 . The O-ring 126 and backup ring 128 seal and isolate the open chamber 28 from the other flow passageways in the valve 10 .
A groove 130 is found in the other end of the seal carrier 16 and is sized and arranged to receive an O-ring 132 and backup ring 134 . The O-ring 132 and backup ring 134 seal and isolate the close chamber 32 from the other flow passageways in the valve 10 .
The bi-directional seal assembly generally identified by the numeral 36 is positioned in the transverse bore 36 of seal carrier 16 . The seal assembly functions when supply pressure (pressure from wellbore fluids) enters the through bore 44 of first seal plate 42 and the through bore 52 of seal plate 50 and is applied to the seal assembly 36 . The seal assembly also functions when function pressure (from the sample collection bottle) enters the longitudinal bore 14 , and the transverse bore 34 in the seal carrier 16 and is applied to the seal assembly 36 . The seal assembly 36 is therefore referred to as “bi-directional” because it functions when exposed to both supply pressure (pressure from wellbore fluids in the well) and function pressure (pressure from the stored wellbore fluids in the sample collection bottle).
The seal assembly 36 includes a first seal cup 160 , a second seal cup 162 , a seal spool 164 , a first O-ring 166 and a second O-ring 168 .
Referring to FIG. 3 , the seal spool 164 is shown in perspective view. The seal spool 164 has a central axle 200 bisected by a circular collar 202 . The axle 200 has a first end 204 and a second opposing end 206 .
Referring to FIG. 4 , the seal spool 164 is shown in section view with two O-rings 166 and 168 . The O-ring 166 fits on the first end 204 of axle 200 and the second O-ring 168 fits on the second end 206 of the axle 200 . The circular collar 202 is formed on an angle of approximately 10°. However, a 90° angle between the collar 202 and the axle 200 also functions satisfactorily.
O-rings are used in two basic applications generally referred to as “static” and “dynamic” by those skilled in the art. The O-rings 166 and 168 in the bi-directional seal assembly 36 are considered as static. In a static seal, the mating gland parts are not subject to relative movement. In the present invention, the transverse bore 34 , the seal spool 164 , and the seal cups 160 and 162 are nonmoving.
O-ring manufacturers, for example Parker Seals of Parker Hannifin Corp. of Lexington, Ky., generally recommend that some squeeze be applied to O-rings for maximum sealing effectiveness. Squeeze can be either axial or radial. The O-rings 166 and 168 shown in FIG. 4 are in a relaxed state. However, when placed in the seal assembly 36 in the transverse bore 34 , the O-rings are typically squeezed axially more than the amount typically recommended by O-ring manufacturers.
In the present invention, a Parker No. 2-004 O-ring is suitable for use as O-rings 166 and 168 . These O-rings are formed from Buna-N 90 durometer material and the maximum operational temperature suggested by Parker is 350° F. Applicants recommend an axial squeeze of 40% or more. The July 1999 Parker O-ring Handbook Design Chart 4-2, a copy of which is included in the Information Disclosure Statement, filed concurrently herewith recommends an axial squeeze for No. 2-004 through 050 of 19 to 32 percent. Design chart 4-2 is for static O-ring sealing. Other O-ring manufacturers, for example, Apple Rubber Products of Lancaster, N.Y., recommends an axial squeeze for an O-ring with a 0.070 cross-section of between 25.5 and 38.5 percent for a static seal. (See page 17 of the Apple Rubber Products Seal Design Catalog, portions of which are included in the Information Disclosure Statement filed concurrently herewith).
Referring to FIG. 5 and FIG. 6 , the first seal cup 160 is shown. The first seal cup 160 has a through bore 220 a portion 222 of which is sized and arranged to receive the first end 204 of the axle 200 of seal spool 164 . The seal cup 160 has a flat sealing surface 224 that seals against flat sealing surface 226 of first seal plate 42 .
Referring to FIG. 7 , an enlarged section view of the seal assembly 36 is shown. O-rings 166 and 168 are squeezed axially about 40% or more against the collar 202 by the seal cups 160 and 162 . The second seal cup 162 has a flat sealing surface 228 formed thereon to seal against an opposing flat sealing surface 230 of seal plate 50 . Seal cup 162 has a through bore 232 , a portion 234 of which is sized and arranged to receive the second end 200 of the axle.
In FIG. 7 , the arrows indicate supply pressure (from wellbore fluids) that passes through bore 44 in the seal plate 42 and bore 220 in first seal cup 160 urging O-ring 166 away from first axle portion 204 and against the transverse bore 34 . Likewise supply pressure (from wellbore fluids) passes through bore 52 in seal plate 50 and bore 232 in second seal cup 162 , urging O-ring 168 away from second axle portion 206 and against the transverse bore 34 . As O-rings 166 and 168 deform against the id of the transverse bore, the supply pressure exerts force against the rear surface 240 of first seal cup 160 and the rear surface 242 of second seal cup 162 . This supply pressure exerted on rear surfaces 240 and 242 creates a metal to metal seal between the seal cup 160 and seal plate 42 and seal cup 162 and seal plate 50 .
After the valve 10 has been opened and wellbore fluids, sometimes at pressures as much as 20,000 psi are stored in the sample collection bottle, the downhole tool is removed from the hole. At the surface, pressure on the outside of the tool at seal level is one atmosphere, but the pressure in the sample collection bottle will still be at wellbore pressure, perhaps 20,000 psi. For this reason the seal assembly 36 must be bi-directional and be able to seal when function pressure from the sample collection bottle exceeds ambient pressures surrounding the downhole tool.
In FIG. 8 , the arrows indicate function pressure (from the sample collection bottle) that passes through the longitudinal bore 14 and passes between the transverse bore 34 and first seal cup 160 and second seal cup 162 , urging O-rings 166 and 168 into contact with axle portions 204 and 206 and away from transverse bore 34 . As O-ring 166 and 168 deform against the id of the axle portions 204 and 206 , function pressure exerts force against the rear surface 240 of seal cup 160 and the rear surface 242 of seal cup 162 . The function pressure exerted on rear surfaces 240 and 242 creates a metal-to-metal seal between the seal cup 160 and seal plate 42 and seal cup 162 and seal plate 50 .
O-rings 166 and 168 are squeezed axially more than the amount recommended by the manufacturers because the O-rings 166 and 168 perform actual purpose. First, the O-rings 166 and 168 act as springs and second, they act as seals. At low pressures, it is important to ensure that first seal cup 160 engages first seal plate 42 at low pressures. Because O-ring 166 is squeezed axially, it exerts force against the seal cup 160 like a spring to ensure contact. However, sealing between seal cup 160 and seal plate 42 , at higher pressure, is due to forces exerted on the rear 240 of the seal cup 160 by either supply or function pressure.
Likewise it is important to ensure that second seal cup 162 engages second seal plate 50 at low pressures. Because O-ring 168 is squeezed axially, it exerts force against the seal cup 162 like a spring to ensure contact. However sealing between seal cup 162 and seal plate 50 , at higher pressures, is due to forces exerted on the rear 242 of the seal cup 162 by either supply or function pressure.
In FIGS. 7 and 8 , seal cup 160 has a lip 250 that extends into the through bore 220 . Likewise seal cup 162 has a lip 252 that extends into through bore 254 . In an alternative embodiment, the lips 250 and 252 are eliminated.
FIG. 9 is a section view of an alternative embodiment 254 of the seal assembly. The seal assembly 254 is the same as seal assembly 36 , except first seal cup 256 and second seal cup 258 do not have lips 250 or 252 . In all other respects, the seal assembly 254 functions in the same fashion as seal assembly 36 .
FIGS. 10–15 show an additional embodiment of the present invention which is similar in construction and operation to the valve embodiments disclosed above. Like numbers throughout the various figures designate like or similar parts that are described above. Because these parts are described above, those parts need not be described again herein. The embodiment shown in FIGS. 10–15 show back-up rings 301 and 302 to provide additional support for the O-rings 166 and 168 carried by the seal spool 164 . There are a pair of back-up rings 301 and 302 positioned at each end portion 204 and 206 of the axle 200 . The rings 301 , 302 are preferably made of PEEK (poly-ether-ether-ketone). The use of the back-up rings 301 , 302 permit the valve to be operated at higher pressures and temperatures than valves without the back-up rings. The collar 202 separates the two O-rings, 166 and 168 . The rings 301 are outer positioned rings and the rings 302 are inner positioned rings. The pair of rings 302 are each positioned adjacent a respective end portion 204 , 206 of the spool 200 . These rings engage the outer perimeter or surface of axle 200 and have a first surface 310 for engagement with a respective surface 240 or 242 of the respective seal cup 160 or 162 . The rings 302 also have a surface 312 which is generally cylindrical and is in engagement with an exterior surface or outer perimeter of the axle 200 . A third surface 314 extends between ends of the surfaces 310 and 312 providing a surface for engagement with the respective O-ring 166 , 168 at least when the O-rings are in the position shown in FIG. 13 when the valve is open. The rings 302 prevent the O-rings 166 , 168 from flowing or deforming (extruding) into the space between the seal cup 160 , 162 and the respective end portions of the axle 200 . The rings 302 are positioned around and in contact with the first and second end portions 204 , 206 of the axle 200 , 204 , 206 between the respective seal cup 160 , 162 and the respective O-ring.
The back-up rings 301 are generally triangularly shaped, having surfaces 320 for engagement with the respective surface 240 , 242 of the seal cups 160 , 162 , respectively. Each of the rings 301 has a second surface 322 for engagement with the surface defining the bore 34 . The rings 302 thereby bridge the gap between the seal carrier 16 and the respective seal cups 160 , 162 . When an O-ring 166 , 168 is pressurized or its inner perimeter is moved to an outer or expanded condition as shown in FIG. 11 . The use of the rings 301 prevent the O-ring from flowing or deforming (extruding) into the gap between the surface defining the bore 34 and the outer perimeter of the seal cups 160 and 162 . The rings 301 have a third surface 324 for engagement with the outer surface of the respective O-ring 166 , 168 .
Each of the O-rings 166 , 168 is compressed axially by its respective seal cup 160 and 162 and their respective pair of back-up rings 301 , 302 against the collar 202 . The collar 202 has generally oppositely facing surfaces that engage the O-rings. The surfaces of the collar 202 engaging the O-rings may be generally normal (0°) to the longitudinal axis of the axle 200 or may be inclined toward the center of the collar 202 at an angle of up to 10°. When the O-rings are compressed between the respective seal cup and collar 202 and their respective back-up rings 301 and 302 , the O-rings act not only as seals but as springs urging the seal cups 160 , 162 into contact with the opposing seal plates 42 and 52 .
The O-rings 166 , 168 move radially inwardly and outwardly depending upon the source of pressure. When the source of pressure is in the direction of the arrows seen in FIG. 11 the O-rings move to an outward or expanded position. When the pressure is applied in the direction of the arrows in FIG. 13 , the O-rings 166 , 168 move inwardly to engage the axle 200 . Preferably, there is some clearance provided so that the seal plates 42 , 52 and seal cups 160 , 162 can move inwardly. The seal plates 42 and 52 are provided with T-heads that engage a shoulder to prevent excessive inward movement and over-compression or pressurization of the O-rings 166 and 168 .
When the seal assembly is exposed to supply pressure, as discussed above, and as seen in FIG. 11 , the seal cups 160 , 162 energize the respective O-ring forcing it out of contact with the axle and into sealing contact with the surface defining the transverse bore 34 of the seal carrier so supply pressure can force both the seal cups into sealing engagement with the seal plates. When the seal assembly is exposed to function pressure as seen in FIG. 13 , the function pressure enters the transverse bore 34 of the seal carrier energizing the O-rings, forcing them out of contact with the surface defining the transverse bore 43 and into sealing contact with the seal spool 164 , the axle 200 , the rings 302 and the seal cups 160 , 162 , so the function pressure can force both seal cups into sealing contact with the seal plates, as disclosed above. To effect sealing, the O-rings are squeezed axially more than 38.5% between the collar and the seal cups.
Thus, the seal arrangement shown in the embodiment of FIGS. 10–15 , and notably that shown specifically in FIG. 10 , replaces the seal arrangement shown in FIGS. 1–9 , and more specifically, for example, that shown in FIG. 4 . | A bi-directional seal assembly can be used in various types of cartridge valves including dirty fluid valves and a variety of other valves. The present seal assembly utilizes a seal spool, two O-rings and opposing seal cups. Back-up rings are provided to engage the O-rings to control deformation of the O-rings. The O-rings are compressed during manufacture of the seal assembly and the valve more than typically recommended by O-ring manufacturers. Because of this compression, the O-rings serve a dual function. At lower pressures, the O-rings act as a spring causing the seal cups to contact the opposing seal plates and at higher pressures they act as seals between the seal assembly and the valve. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for the manufacture of a key top for a push button switch preferably used in input devices such as cellular phones and keyboards.
2. Description of Related Art
Switches having a structure consisting of a rubber contact switch and a key top installed on the top portion of the key switch have been generally used as push button switches employed in cellular phones and the like.
Push button switches are also required to have excellent appearance, and the demand for metallic-like switches of this type has recently increased. Technology relating to methods for the manufacture of metallic-like push button switches (referred to as “metallic switches” hereinbelow) of an illumination type, which are used in portable phones, was disclosed in Examined Japanese Patent Application No. 3-23915 and Unexamined Japanese Patent Application 2000-176659. In accordance with this technology, a metal layer is formed on a key top and then part of the metal is evaporated and dissipated with a laser to obtain letters, symbols and the like. Furthermore, when colored, e.g., red or blue, metallic switches rather than switches with metallic colors are manufactured, a transparent colored layer is formed on the key top surface, then a metal layer is formed, and only a metal layer is evaporated with a laser.
However, with the above-described method, because laser processing is employed, mass production is difficult to Implement. Furthermore, since the entire procedure, from the first to the last stage, is conducted on the key top, if a defect occurs in the last stage, all the preceding operations become useless and the productivity is poor.
Furthermore, when a colored metallic button is manufactured, though the metal layer is removed with a laser, the transparent colored layer is not removed and remains as is. Thus, in order to remove the metal layer, a short-wavelength laser radiation such as that of YAG (yttrium aluminum garnet) laser has to be used, such short-wavelength laser radiation penetrating through plastics. Therefore, the problem associated with such a method is that the transparent colored layer remains without changes and the color of the light that penetrates through the metallic button is restricted to the color of the colored layer.
SUMMARY OF THE INVENTION
With the foregoing in view, it is an object of the present invention to provide a method for the manufacture of a metallic switch which allows high productivity. It is also an object of the invention to provide a colored metallic switch with a high added value, in which no limitation is placed on the color of the transmitted light.
The method for the manufacture of a metallic switch in accordance with the present invention, which attains the above-described objects, comprises the steps of forming a metalizing layer on the surface of a transfer substrate, forming a first transparent printed layer patterned as letters, numbers, symbols, pictures, and the like and having resistance to etching on the metalizing layer, removing the metalizing layer which is not masked by the transparent printed layer by etching, placing the transfer substrate on the plastic key top body, and transferring the transfer layer consisting of the metalizing layer and masking material layer after etching onto the key top body.
Thus, transferring of the masking material (first transparent printed layer) which, within the framework of the conventional technology, was considered merely as a protective layer for etching and was removed after etching onto the key top body integrally with the metalizing layer, makes it unnecessary to remove the masking material. Moreover, the metalizing layer which has a low strength and can be easily fractured is protected and reinforced by the transparent printed layer. Therefore, transferring of the metalizing layer can be conducted with high stability, and a metallic switch can be manufactured in an easy and efficient manner.
The transfer layer may be transferred either on the front or rear surface of the key top body, and the transfer operation is conducted so that the first transparent printed layer is brought in contact with the key top body. When the transfer layer is transferred onto the front surface of the key top, the metalizing layer is at the front surface side of the key top and a metallic switch with a color of the metalizing layer is obtained. When the transfer layer is transferred onto the rear surface of the key top, the transparent printed layer is at the front surface side of the key top and, if a colored transparent printed layer is used, the metalizing layer is colored and a colored metallic switch is obtained.
In order to transfer the transfer layer, a hot press method can be used. If the first transparent printed layer demonstrates stickiness during heating, the direct transfer to the key top body is possible. However, if a transparent adhesive layer is formed on the transparent printed layer, the transfer layer can be transferred onto the key top body with higher reliability and without the danger of misalignment.
No specific restriction is placed on the transfer substrate, provided that it is highly flexible and resistant to beat and etching. Examples of suitable materials include films or sheets of plastics with high heat resistance and mechanical strength such as PET (polyethylene terephthalate). If such flexible transfer substrate is used, even when the transfer layer is formed on the key top body having peaks and valleys, the transfer substrate follows the curved surface and can be reliably laminated onto the key top body. Therefore, the number of printing defects occurring in the metalizing layer and first transparent printed layer can be decreased by comparison with the case when the printed layer is formed directly on the key top body.
In accordance with the present invention, the metalizing layer and transparent printed layer are formed separately from the key top body, and those layers are transferred onto the key top only in the final stage. Therefore, the defect ratio in the key tops as a final product can be reduced. Furthermore, the metalizing layer and transparent printed layer are formed on a film- or sheet-like substrate rather than on the key top body having high rigidity. Therefore, the substrate can be supplied as a roll. If the substrate is coiled up into rolls and stored after the metalizing layer and transparent printed layer have been formed, the transfer substrate serves as a protective layer for both layers. Therefore, the substrate can be handled easily and space for manufacturing equipment can be saved.
The first transparent printed layer is patterned as letters, numbers, symbols, pictures, and the like, and the metalizing layer in the portion thereof which is not covered with the printed layer is removed by etching. Therefore, when the transparent printed layer is colored and the transfer layer is transferred onto the rear surface of the key top body, only portions where the metalizing layer is present are colored, and portions from which the metaling layer has been removed are in a state in which the transparent printed layer has also been removed. Therefore, a metalizing switch with a high added value can be provided without placing a limitation on the color of the light that passes through the switch, while coloring the metalizing layer portions.
Furthermore, if a second transparent printed layer is formed on the surface of a transfer substrate prior to the step of forming the metalizing layer and then the transfer layer containing the second transparent printed layer is transferred onto the back surface of the key top body, a key top is obtained in which the metalizing layer is covered and protected by the second transparent printed layer. Thus, the damage, peeling, or modification of the metalizing layer can be prevented.
If a colored layer is used as the second transparent printed layer in the above-described process, the light that passes through the metallic switch can be colored appropriately. The second transparent printed layer may have a single color or it may be multicolored. When coloration is the object, printing may be conducted on a portion of the transfer layer.
More specifically, in a push button switch of a control unit of a cellular phone, a colored first transparent printed layer is used, a green printed material is employed for a button with a picture of a receiver indicating the communication state, a red printing material is employed for a button with a picture of receiver indicating the end of communication, and colorless transparent printing materials are used for other buttons as the second transparent printer layer. Therefore, a colored metallic switch can be obtained which has three different colors: green and red colors of transmitted light and the color of light-emitting elements. Thus, the added value can be increased and a metallic switch with excellent endurance can be obtained because the metalizing layer is covered and protected with the second transparent printer layer.
Furthermore, if the transfer substrate is a material having poor adhesion to the metalizing layer, for example, from a PET film, the metalizing layer can be directly formed on the substrate surface. However, if a parting agent is coated in advance on the surface of the transfer substrate, transfer defects can be prevented.
No specific limitation is placed on the material of the key top body. Thus, hard plastics, soft plastics, or rubber material can be used, provided that they are transparent.
The term metalizing layer means a metal film formed by vapor deposition, sputtering, ion plating, electrolytic plating and the like. Among those methods, a vapor deposition method is typically used. No limitation is placed on the type of the metal, but aluminum is preferably used. The metalizing layer formed from aluminum has a silver color, but this color can be changed into a variety of colors by forming a colored transparent printed layer.
No specific limitation is placed on the thickness of the metalizing layer. However, the preferred thickness facilitating etching and also allowing the metalizing layer to serve as a shield for light from a light source installed inside the casing is 350-500 Å.
The printed materials used for the first and second transparent printed layer can be used without any specific limitation, provided that they are resistant to the below-described etching solution and protect the metalizing layer coated on the transparent printed layer from the etching solution. Etching resists can be advantageously used for this purpose. When the transfer layer is transferred onto the back surface of the key top body, if the first transparent printed layer is colorless and contains no coloring material, a colorless metallic switch with an as-is metalizing layer is obtained. When coloring materials such as pigments, dyes, and the like are used, a colored metallic switch is obtained. Furthermore, the transfer material such as an etching resist may be in the form of an ink and a pattern printing can be conducted, for example, by a screen printing process. When the transfer material is in the form of a photocurable film, it is possible to conduct exposure followed by development.
Furthermore, the symbol pattern such as letters, numerals, pictures, and the like formed by the first transparent printed layer may also be obtained by printing a patterned portion and then removing the surrounding metalizing layer. However, it is preferred that an empty symbol be obtained by printing the portions outside of the pattern and removing the metalizing layer of the pattern portions. In such a case, the light passing through the switch brings the symbol to the front, thereby providing for an excellent appearance. Furthermore, since the etching zone can be decreased, the service life of the etching solution can be extended.
The etching solution may be appropriately selected according to the type of the metalizing layer. For example, when the metalizing layer is made of aluminum, an alkaline aqueous solution such as 5% aqueous solution of sodium hydroxide or an acidic aqueous solution such as hydrochloric acid are preferably used.
As described above, in the key top in which an empty-symbol printed layer consisting of two layers, namely, a first transparent printed layer and a metalizing layer, is formed on the back surface of a key top body, the front surface is covered with the key top body and therefore protected from damage. Furthermore, if a colored printed material is used, a colored metallic switch can be obtained which is free from limitations imposed by the color of transmitted light.
Furthermore, if the second transparent printed layer is formed on the back surface of the empty-symbol printed layer and colored printed materials of different colors are used for the first and second transparent printed layers, then the transmitted light can be various colors, and a colored metallic switch can be obtained which is a colorful type unknown in the prior art and which provides a high added value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 (A) through 1 (G) are diagrams illustrating the steps of a key top production method of an embodiment of the present invention.
FIG. 2 is a schematic diagram illustrating the utilization of a key top.
DETAILED DESCRIPTION OF THE INVENTION
Reference numeral 1 denotes a transfer substrate, reference numeral 2 denotes a second transparent printed layer, reference numeral 3 denotes a metalizing layer, reference numeral 4 denotes a first transparent printed layer, reference numeral 5 denotes an adhesive layer, reference numeral 6 denotes a key top body, and reference numeral 7 denotes a key top. FIG. 1 and FIG. 2 illustrate a preferred embodiment of the present invention. FIG. 1 illustrates the key top manufacturing process. FIG. 2 is a schematic diagram illustrating the utilization mode of the manufactured key top.
Various stages of the manufacturing process shown in FIG. 1 will be described below. In the present preferred embodiment, a PET film is used as a transfer substrate 1 , and a silicone-based parting agent is coated on the front surface of the transfer substrate 1 . Then, as shown in FIG. 1 ( a ), a colored second transparent printed layer 2 is formed on the front surface of the transfer substrate 1 and, as shown in FIG. 1 ( b ), aluminum is deposited on the front surface of the second transparent printed layer by a vapor deposition method so as to form a metalizing layer 3 .
Then, as shown in FIG. 1 ( c ), an empty-symbol pattern is formed with a first transparent printed layer 4 colored in a color different from that of the second transparent printed layer 2 . As shown in FIG. 1 ( d ), the metalizing layer 3 which is not covered with the first transparent printed layer 4 is etched by an alkaline solution. As a result, an empty-symbol printed layer consisting of the first transparent printed layer 4 and metalizing layer 3 is formed.
Then, as shown in FIG. 1 ( e ), an adhesive is coated on the front surface of the first transparent printed layer 4 so that an adhesive layer 5 is formed. As a result, a transfer material is produced in which a transfer layer is formed on the transfer substrate, this transfer layer consisting of the following four layers: adhesive layer 5 , first transparent printed layer 4 , metalizing layer 3 , and second transparent printed layer 2 . The transfer material thus produced is stored upon winding into a roll, and may be appropriately supplied to a subsequent processing step.
The transfer material thus produced is placed on the back surface of the key top body 6 consisting of transparent plastic such as polycarbonate resins or acrylic resins so that the adhesive layer 5 is brought in contact with the key top body, as shown in FIG. 1 ( f ), and the transfer layer is transferred by a thermal pressing method. In this process, various thermal pressing methods can be appropriately used. Examples of such methods include an up-down method, a thermal roil method, a press-roll method by which the overlapping transfer material is pressed against the side of the key top body, and an in-mold method by which transfer is conducted simultaneously with the formation or the key-top body. Upon completion of the transfer, as shown in FIG. 1 ( g ), the transfer substrate 1 is removed which makes it possible to obtain a key top 7 with a transfer layer laminated thereon.
An example of the utilization mode of the key top 7 obtained in the above-described manner is shown in FIG. 2 . This figure shows a push button switch used as an operation unit of a cellular phone. The operation unit consists of several switches. To simplify the explanation, only one switch is considered and a cross section thereof is schematically shown in the figure.
As shown in the figure, the push button switch is composed of a rubber contact switch 9 and the key top 7 above the switch 9 . A top portion of the key top 7 protrudes from an opening 8 a provided in a casing 8 . A flange 7 a having a diameter somewhat larger that that of the opening 8 a is formed at the lower end periphery of key top 7 . This flange prevents key top 7 from being pushed through the opening 8 a, and also prevents leakage of the light emitted by a light source A disposed inside the casing 8 through a gap between the opening 8 a and key top 7 . Therefore, the key top 7 may be placed above the rubber contact switch 9 , but if it is secured with a transparent adhesive, a push button switch with a stable operation feeling can be obtained.
The rubber contact switch 9 is made of a transparent rubber and it comprises a thin elastic portion 9 b having a skirt-like shape and a contact element 9 a provided on the back surface of the top portion thereof. When the push button switch is pushed, the movable contact element 9 a is brought in contact with a fixed contact element 9 c provided on a printed substrate C and the switch is turned ON.
The key top 7 has a configuration in which the above-described transfer layer having a four-layer structure is transferred onto the back surface of key top body 6 . The transfer layer is obtained by successively laminating (from the key top body 6 side) the adhesive layer 5 , first transparent printed layer 4 , metalizing layer 3 , and second transparent printed layer 2 . Therefore, light emitted from the light source A passes through the transparent rubber contact switch 9 and second transparent printed layer 2 , but most of the light is reflected by the metalizing layer 3 , and a part of the light is emitted to the outside through an empty symbol portion B formed by etching of the metalizing layer 3 .
At this time, the transmitted light from the empty symbol portion B passes through and is colored by the second transparent printed layer 2 , and the portion of the transfer layer surrounding the empty symbol portion B is recognized as a non-transparent colored metallic portion colored by the first transparent printed layer.
The present invention is not limited to the above-described embodiment, and it goes without saying that various amendments and modifications can be made without departing from the scope of the present invention. For example, the transparent printed layer used in the preferred embodiment may be only colored and also have a variable degree of transparency. More specifically, if the second transparent printed layer is provided with a milk-white coloration reducing its transparency, the transmitted light becomes soft and a switch with excellent appearance can be obtained.
As described above, in accordance with the present invention, the first transparent printed layer functioning as a masking material in the etching process is transferred onto the key top body as a transfer layer in which it is integrated with a metalizing layer. As a result, the process of removing the masking material becomes unnecessary, the metalizing layer, which has a lower strength and can be easily fractured, is protected and reinforced by the first transparent printed layer, the metalizing layer can be transferred with high stability, and a metallic switch can be produced with high stability and in an easy manner.
Furthermore, when the transfer layer is transferred onto the back surface of the key top, the first transparent printed layer becomes a front surface layer. If a colored transfer material is used, a portion where the metalizing layer is present is colored, but a portion from which the metalizing layer has been removed is not colored, and a colored metallic switch with a high added value can be obtained.
Furthermore, if a second transparent printed layer is formed on the front surface of the substrate prior to the formation of the metalizing layer, and a layer additionally containing the second transparent printed layer is transferred as a transfer layer, a key top is obtained in which the metalizing layer is covered and protected by the second transparent printed layer. As a result, fracture, peeling, and modification of the metalizing layer can be prevented.
Moreover, if a colored layer is used as the second transparent printed layer, the light passing through the metallic switch can be colored appropriately and a metallic switch with a high added value can be obtained. | The object of the present invention is to provide a method of manufacturing a metallic switch with high productivity. A transparent printed layer ( 4 ) is patterned and formed on a metalizing layer ( 3 ) formed on the front surface of a transfer substrate, and the metalizing layer ( 3 ) is subjected to etching. The metalizing layer ( 3 ) and the transparent printed layer ( 4 ) are integrally transferred onto a key top body ( 6 ). As a result, the metalizing layer, which has a low strength and can be easily fractured, is protected and reinforced by the transparent printed layer ( 4 ), the metalizing layer can be transferred with high stability, and a metallic switch is manufactured in an easy manner and with good efficiency. | 8 |
This application is a continuation of U.S. patent application Ser. No. 13/036,340 filed Feb. 28, 2011 which claims priority to U.S. Provisional Patent Application Ser. No. 61/308,728, filed Feb. 26, 2010. All extrinsic materials identified herein are incorporated by reference in their entirety.
FIELD OF THE INVENTION
The field of the invention is wearable lumbar supports.
BACKGROUND
Orthotic devices are typically provided for partial or substantial immobilization of the torso to stabilize the back. Some orthotic devices are back braces that fit around the torso around the lumbar area. When worn properly, a body brace can lend additional support to the abdomen and the spinal column to achieve spinal stability. However, for many users body braces are difficult to appropriately position and fasten. For example, U.S. Pat. No. 4,640,269 to Goins provides a back brace that is tightened around the body by threading a Velcro strap through a loop and pulling the strap backwards towards the user's posterior. The awkward angle of the strap prevents users from fully tightening the strap themselves and requires a third party to assist in the tightening process.
Goins and all other extrinsic materials identified herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
US 2007/0017945 to Willis teaches a body brace that wraps around a user's lumbar region and has a belt with a strap that pulls forward to fit the brace around the user. Willis' body brace is easier to tighten since the strap tightens by pulling forward, which is a natural body movement. Willis, however, fails to contour to body shapes of different shapes and sizes, for example differently shaped hips and different lordotic curves.
U.S. Pat. No. 6,213,968 to Heinz teaches a custom fitted orthotic device with cables with a split lumbar support that is tightened around a lumbar region using pulleys and cords. Heinz, however, provides either rigid support or flexible support, and fails to allow the lumbar support to flex and bend into the lumbar curve while the lateral support remains rigid. These and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
It has yet to be appreciated that stiff lumbar supports could have flexible joints that wrap around a patient's curvature to provide a stiff support that is custom fit.
Thus, there is still a need in the art for a body brace that conforms to body shapes of different shapes and sizes.
SUMMARY OF THE INVENTION
The present invention provides apparatus, systems, and methods in which one could use a brace to support the lumbar region of a patient by providing a lumbar support having a joint between upper and lower sections of the lumbar support. The upper and lower sections of the lumbar support are generally rigid with respect to the joint such that the joint can move anteriorly relative to the coronal plane of the body such that the joint folds into the curve of the lumbar region and the upper and lower sections “hug” the lumbar region. As used herein, the term “rigid” refers to a material that will not fold in half without permanently deforming the shape of the material, such as by snapping or breaking. A rigid material may bend slightly under pressure and return to its previous form when such pressure is removed, but will not fold in half. Contrast this with a “flexible” material, which could be unfolded to a planar form and could be folded in half with ease, without permanently deforming the shape of the material.
The upper and lower sections of the lumbar regions preferably have right and left sections that are coupled together by upper and lower mechanically advantaged systems. Contemplated mechanically advantaged systems include series of pulleys, gears, levers, screws, or combinations thereof that provide force to an adjustment mechanism. Preferably, the advantaged adjustment mechanism is mechanically advantaged more than 2:1, and is more preferably mechanically advantaged at 4:1 or more, additional pulleys or longer levers could easily increase the mechanical advantage ratio of the mechanism. Exemplary mechanically advantaged systems are further described in co-pending U.S. application Ser. Nos. 12/394867, 10/977726, and 10/440525, which are each incorporated herein by reference.
An exemplary mechanically advantaged system includes pulleys and cords that work to draw the left and right sections of the support region towards one another, towards the front/anterior side of the wearer. Such pulley systems could have 2, 3, 4, 5, or more pulleys, depending on the size and strength needed in such a device. In order to prevent the right and left sections of the lumbar support from pulling too far apart from one another, a limiter is preferably provided that prevents the left and right sections from moving a threshold distance away from one another. For example, a limiter could be a cloth, rope, or other material that couples the right and left sections without stretching. The limiter is preferably made from a compressible material to allow the right and left sections to fold over one another during storage, and also preferably includes a hole along the sagittal midplane of the wearer to allow a doctor to access the lumbar region of the wearer without removing the brace itself.
One or more optional extenders could be coupled with the lumbar support to extend the effective length, width, or height of the lumbar support, allowing for greater flexibility in the form and function of the brace. The optional extenders could alter the length, width, or height of the lumbar support by a variety of lengths, for example at least 2 inches, 5 inches, 10, inches, or 15 inches. Multiple extenders could be configured to attach to one another, allowing for a variety of extension configurations for wearers of different sizes and/or needs. Rigid reinforcing supports could also be coupled to the lumbar support, overlapping the joint, to prevent the flexible joint from bending in certain configurations.
The body brace preferably also has a rigid lateral support that reinforces the wearer's oblique muscles. Preferably, the rigid lateral support has a surface area greater than 4, 5, 10, 15, or 20 square inches. In an exemplary embodiment, the rigid lateral support extends anteriorly past a midline of the wearer. The lateral support may have an optional extender that couples to the lateral support to extend an effective length, width, or height of the lateral support, and/or may overlap with sections of the lateral support to reinforce a rigidity of the lateral support. Such optional extenders could alter the length, width, or height of the lumbar support by a variety of lengths, for example at least 2 inches, 5 inches, 10, inches, or 15 inches. Multiple extenders may be attached to one another to extend the lateral support for a plurality of lengths, or to reinforce the lateral support for a plurality of rigidity strengths.
The present invention provides apparatus, systems and methods in which a body brace is configured to conform and fit a variety of body shapes of different shapes and sizes.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a rear plan view of an embodiment of a quick draw brace.
FIG. 2 is a front plan view of the quick draw brace of FIG. 1 .
FIG. 3 is a rear plan view of the quick draw brace of FIG. 1 , with fitting belts attached to the rear side of the lateral support.
FIG. 4 is an exploded view of the quick draw brace of FIG. 3 .
FIG. 5 is a plan, rear view of the quick draw brace of FIG. 1 , with fitting belts attached to the front side of the lateral support.
FIG. 6 is an exploded view of the quick draw brace of FIG. 5 .
FIG. 7 is a plan view of the quick draw brace of FIG. 6 , with the fitting belt folded over.
FIG. 8 is a perspective view of the brace of FIG. 1 with the lumbar support in a bent position.
FIG. 9 is a rear plan view of an embodiment of an extender.
FIG. 10 is a front plan view of an embodiment of the extender of FIG. 9 .
FIG. 11 is a rear plan view of the quick draw brace of FIG. 7 juxtaposed with the extender of FIG. 9 .
FIG. 12 is a rear plan view of the quick draw brace of FIG. 7 with the extender of FIG. 9 attached to the quick draw brace.
FIG. 13 is a rear plan view of a reinforcement panel.
FIG. 14 is a front plan view of the reinforcement panel of FIG. 13 .
FIG. 15 is a rear plan view of the extender of FIG. 9 juxtaposed with the reinforcement panel of FIG. 13 .
FIG. 16 is a rear plan view of the extender and reinforcement panel of FIG. 15 juxtaposed with the quick draw brace of FIG. 7 .
FIG. 17 is a rear plan view of the extender, reinforcement panel, and quick draw brace of FIG. 16 coupled with one another.
FIG. 18 is an enlarged, exploded view, showing the cord guide parts within the upper left and right sections of the brace of FIG. 1 .
FIG. 19 is a perspective view of the upper left and right sections of FIG. 18 in the assembled configuration.
DETAILED DESCRIPTION
FIGS. 1 and 2 show a quick draw brace 100 with a lumbar support 110 , lateral supports 120 and 130 , cords 140 and 150 , and limiter 160 . Lumbar support 110 is split into upper left section 111 , lower left section 112 , upper right section 114 , and lower right section 115 . Upper left section 111 and lower left section 112 are configured to pivot with respect to one another along flexible joint 113 , and likewise upper right section 114 and lower right section 115 are configured to pivot with respect to one another along flexible joint 116 . Upper left section 111 , lower left section 112 , upper right section 114 , and lower right section 115 are all preferably rigid or semi-rigid in order to provide support to the upper lumbar curve and the lower lumbar curve of the wearer.
Lateral supports 120 and 130 are preferably made of a semi-rigid or rigid material to provide lateral support to a user. While the current embodiment shows lateral support 120 being wholly contiguous with left lumbar support sections 111 and 112 , the lateral support could be made separately from the lumbar supports without departing from the scope of the current invention. It is preferred that the lateral support is a semi-rigid material that is greater than 4 or 5 inches so that the lateral support would pass the midline of the wearer.
In the current embodiment, flexible joints 113 and 116 are created by creating a thin peninsula of a substantially rigid plastic polymer separate from the lateral supports 120 and 130 . Since the peninsula is so thin (approximately 1.5 centimeters across), the upper and lower sections are able to bend along the joint, whereas they would not be able to if the peninsula was much wider. As shown in FIG. 8 , as the upper and lower sections bend inward, the lateral section does not also bow inward because of the shape of the peninsula. In reality, lateral section 130 bows outward slightly, which is largely contained when cord 150 is pulled against lateral section 130 . One skilled in the art would understand that other flexible joints could be used, for example by using a cloth lumbar support or by adding a hinge or series of hinges to a more rigid peninsula.
Cords 140 and 150 are attached to pulleys (shown in FIGS. 18 and 19 ) in the upper and lower sections in a similar manner to the pulleys described in US2009/0192425 and U.S. Pat. No. 7,001,348. This creates a mechanically advantaged system such that when a wearer pulls cords 140 and 150 , these sections could then fold anteriority until the flexible joint engages the lordotic curve of the wearer's posterior side, allowing for a tighter fit. Since the lateral supports 120 and 130 are coupled to the lumbar support 110 via thin, semi-rigid peninsulas, the lateral supports do not bend when the cords are pulled. Preferably, the pulley system comprises an elastic band or spring that will automatically retract the cord when a force ceases to be applied to the cord.
Cords 140 and 150 terminate in handles 142 and 152 , which each have hook and loop attachments that could be attached to left and right adjustment mechanisms 310 and 320 shown in FIGS. 3-8 . Left adjustment mechanism 310 and right adjustment mechanism 320 preferably both have loop material along a majority of their lengths along the front side, to allow cord handles 142 and 152 to be attached to any portion of the adjustment mechanism. Right adjustment mechanism 320 also has hook attachments along its tip to allow it to mate with the front side of left adjustment mechanism 310 when wrapped around a wearer.
Limiter 160 is an underlying cloth that lumbar support 110 is attached to. Since limiter 160 is made of a substantially inelastic material, limiter 160 prevents cords 140 and 150 from being pulled too far towards the holes, effectively controlling the minimum distance that the cords can be retracted. As used herein, a 5 inches (12.7 cm) of a “substantially inelastic material” does not stretch more than 3 mm without tearing. Limiter 160 also has hole 162 , which allows access to the lumbar region of the wearer for emergencies, and also prevents direct force from being applied to the lumbar region in case of severe injury.
Right adjustment mechanism 320 attaches to lateral support 130 via holes 132 . As shown in FIG. 6 , hole 132 comprises two opposing bolt recesses 133 and 134 . This allows right adjustment mechanism to attach to a front side of a hole as shown in FIG. 4 , or attach to the rear side of a hole as shown in FIG. 6 . Allowing right adjustment mechanism 320 to attach to either the front or a rear side of a hole doubles the adjustment length as compared to an adjustment mechanism that merely attaches to one side of the lateral support. It is contemplated that other methods of attaching adjustment mechanisms 310 and 320 to the lateral supports could be used, for example buttons, claps, hooks, or even more hook and loop attachments.
As shown in FIGS. 5 and 6 , when right adjustment mechanism 320 attaches to the rear side of a hole, the adjustment mechanism needs to thread through loophole 136 in order to be orientated correctly for wearing. Loophole 136 is shown as a hole in lateral support 130 , but could be a recess (or an open hole) without departing from the scope of the invention. Since right adjustment mechanism could attach to either a front side or a rear side of the lateral support, the length of right adjustment mechanism could be altered considerably. Additionally, shorter or longer adjustment mechanisms could be provided to allow an even greater variability in sizes. The holes could also be used to attach other lateral supports to accommodate larger wearers and extend the length even further.
The effective height and width of lumbar support 110 could be extended using extender 1000 with optional rigid support 1010 and padding 1020 , shown in FIGS. 10 and 11 . Rigid support 1010 preferably overlaps with some of the surface of lumbar support 110 to reinforce the rigidity of lumbar support 110 . While the drawing illustrates that padding 1020 covers hole 1030 , it is preferred that padding 1020 has a hole that matches hole 1030 , preventing any padding from touching the delicate spinal column along the lumbar region, and providing access to the lumbar region. When lumbar support 110 is attached to extender 1000 as shown in FIGS. 12 and 13 , the effective height of the lumbar support and the effective lengths of the lateral supports could be lengthened considerably.
Preferably, the effective height of the lumbar support is lengthened so that the lumbar support provides support from the sacrococcygeal junction to the 9th thoracic vertebra. This effective height is generally greater than 9 inches in an average adult, and may extend more than 10, 11, 12, 13, or 14 inches, depending on the size of the user. In another embodiment, the effective height of the lumbar support could be adjusted by attaching or detaching other extendable support structures.
Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
The effective length that is added by extender 1000 could be further altered by removing lateral extenders 1012 and 1014 , or by replacing the lateral extenders with longer or differently shaped extenders. As shown in FIG. 9 , lateral extenders 1012 and 1014 mate with bolt holes 1022 and 1024 , respectively, and overlap with a portion of the rigid support 1010 to reinforce the strength of a portion of the rigid support 1010 . The rigid support 1010 shown as being constructed from three separate panels—a mid-panel, a left lateral extender 1012 , and a right lateral extender 1014 —the rigid support could be made from more or less portions as needed. Preferably, the rigid support 1010 is made from the same material as lateral supports 120 and 130 , but could be made from different material if needed.
FIGS. 15 and 16 show the front and back portions of detachable small back panel 1600 . Small back panel 1600 is preferably made from a rigid material covered in padding to protect the regions close to the spine. As shown in FIGS. 13-17 , the small back panel could be wrapped around lumbar support 110 to prevent lumbar support 110 from bending into the lumbar curve of the wearer and to add a more rigid support structure to the lumbar region.
FIGS. 18 and 19 show the configuration of a mechanically advantaged system 1800 represented as upper left section 111 and upper right section 114 , which are pulled together using cord 150 . The lower left and lower right sections are constructed in the same manner. The upper left section 111 has an upper left cord guide base 38 , which has three pulleys, shown in the figure as cord guide lobes 40 , 42 , and 44 thereon. In addition, the base 38 has posts 46 and 47 which snap into matching detents (not shown) in cap 56 . The cord guide lobes 40 , 42 , and 44 are half round and are undercut on their half circumference. The under cut is circular in profile and is at least as large as the diameter of the cord. The under cuts are preferably smooth so that cord 150 can be engaged therearound and smoothly moved around the lobes. For smooth movement, it is preferably that the upper left section 111 and upper right section 114 be made of a low friction polymer, such as nylon or Teflon. The upper right section 114 is similar to upper left section 111 , and also has three cord guide lobes 50 , 52 , and 54 on its base 37 , which act as pulleys for cord 150 . The cord 150 has an eye thereon engaged over post 49 on cord guide 114 . The cord 150 engages around love 40 , lobe 52 , and thence lobe 44 to extend out over the base 37 . When the cord 150 is pulled, the upper left section 111 and upper right section 114 are pulled together with a 4-to-1 mechanical advantage (neglecting friction) The cord 150 is preferably a strong cord with low friction characteristics with respect to the cord guide lobes, such as nylon.
In order to hold a cord in place on the lobes, caps 56 and 58 could be used to cover the bases 38 and 37 , respectively. The caps have half round recesses 60 that engage over the lobes. The recess 60 engages over lobe 44 to hold the cord in the undercut below the top of lobe 44 , and hold the cord loop on the post 49 . The caps can be attached in any other suitable way, for example by using adhesives or mating buttons. Other pulley mechanisms are contemplated, for example pulleys mounted on wheels.
Thus, specific compositions and methods of providing aback brace have been disclosed, it should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure. Moreover, in interpreting the disclosure all terms should be interpreted in the broadest possible manner consistent with the context. In particular the terms “comprises” and “comprising” should be interpreted as referring to the elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps can be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. | A back brace is designed to custom fit a wearer in a multitude of different configurations. First, the back brace could have a lumbar support that is split into upper and lower sections that are connected to a flexible joint, allowing the lumbar support to bend towards the spine of the user. The lumbar support is also generally split into left and right sections that are drawn towards one another while the joint bends towards the lumbar curve. This allows the back brace to conform to the lumbar curve of the wearer as a custom fit. Second, the brace could have optional extenders that alter the support length, width, and height of lumbar and lateral supports about the wearer. Third, the brace could have reinforcement support mechanisms that alter the rigidity of various lumbar and lateral supports about the wearer. | 0 |
TECHNICAL FIELD
[0001] This invention relates to devices for detecting a fault in an AC supply, for example residual current devices (RCDs) and arc fault detectors (AFDs).
BACKGROUND
[0002] Residual current devices, which are also referred to as ground fault circuit interrupters (GFCIs), have been in use worldwide for over forty years, and these devices have contributed significantly to the reduction in fatal accidents arising from electric shock. The principle of operation of RCDs will be well known to those versed in the art, but detailed information can be found in the article “Demystifying RCDs”, at www.rcd.ie, which is incorporated herein by reference in its entirety.
[0003] RCDs are fitted with a test device, often a manually operable button, to enable the user to verify the correct operation of the device, but if the RCD fails to trip on operation of the test device the user may be tempted to simply disregard this warning sign of failure or may delay unduly in replacing the RCD. Once the RCD has failed for any reason it ceases to provide any protection and should be replaced immediately.
[0004] It is an object of the invention to provide an RCD, or other fault detecting device such as an AFD, which incorporates means to remove power from the load in the event of the device failing to trip when operated by the test device. This is sometimes referred to as “end of life” operation or an “end of life” condition.
SUMMARY
[0005] According to the invention there is provided a device for detecting a fault in an AC supply, comprising a circuit (CT, 100 ) for detecting a particular type of fault in an AC supply to a load (LD) and providing a corresponding output ( 10 ), means (RLA) responsive to said output ( 10 ) to open a set of load contacts (SW 1 ) to disconnect the load from the supply, test means (TS, Rt, W 2 ) for simulating a supply fault of the said type, and means (C 3 , R 5 , SCR 2 , SOL, SW 2 ) for causing the load contacts (SW 1 ) to open if they do not open in response to the simulated fault within a certain period of time.
[0006] Preferably the detecting circuit comprises a circuit (CT, 100 ) for detecting a differential current in the AC supply to a load (LD), the differential current having a characteristic indicative of a type of supply fault to be detected, and providing a corresponding output ( 10 ), the disconnect means comprises an electromechanical switch (RLA) controlling the load contacts (SW 1 ), the electromechanical switch being responsive to the said output ( 10 ) to disconnect the load from the supply by opening the load contacts (SW 1 ), and the test means (TS, Rt, W 2 ) simulates the supply fault by causing a differential current, having a characteristic indicative of the said type of fault, to flow in the detecting circuit in the absence of the supply fault.
[0007] In the present context an electromechanical switch is an electrical switch with mechanical contacts which are operated (i.e. opened and/or closed) by a magnetic field produced by current flowing in a coil, usually a solenoid.
[0008] Preferably the means for causing the load contacts (SW 1 ) to open comprises a charge storage device (C 3 ) which is connected to the supply for charging up during periods when the differential current is caused to flow in said detecting circuit by said simulating means, said certain period of time after which the load contacts (SW 1 ) are caused to open being the time taken for the voltage on the charge storage device (c 3 ) to reach a predetermined level sufficient to cause a solid state switch (SCR 2 ) to change state, the load contacts (SW 1 ) being caused to open in response to the change of state of the solid state switch (SCR 2 ).
[0009] More preferably the electromechanical switch (RLA) may be of a type whose contacts (SW 1 ) are held normally-closed by a current flowing through the switch at least when the supply is at or above a certain minimum voltage, and the change of state of the solid state switch (SCR 2 ) causes the flow of current through the electromechanical switch (RLA) to be interrupted so as to open the load contacts (SW 1 ).
[0010] In such a case the fault detecting device may include a further electromechanical switch (SOL) having normally-closed contacts (SW 2 ) in series with the first electromechanical switch (RLA), and wherein the further electromechanical switch (SOL) is responsive to the change of state of the solid state switch (SCR 2 ) to open the normally-closed contacts (SW 2 ) of the further electromechanical switch (SOL).
[0011] Alternatively the fault detecting device may include a fuse (F 1 ) in series with the first electromechanical switch (RLA), and wherein change of state of the solid state switch (SCR 2 ) causes a current to flow through the fuse sufficient to blow the fuse.
[0012] As used herein, the term “fuse” means any component intended to go open circuit or high impedance in response to a surge current, and includes not only conventional melting type fuses but also, for example, PTC devices.
[0013] Preferably a further electromechanical switch (SOL 2 or PMR) is coupled to the same load contacts (SW 1 ) as the first electromechanical switch (SOL 1 ), and the change of state of the solid state switch (SCR 2 ) causes the further electromechanical switch (SOL 2 or PMR) to open the load contacts (SW 1 ).
[0014] In such a case the change of state of the solid state switch (SCR 2 ) may cause a fuse (F 1 ) to blow, the load contacts (SW 1 ) being caused to open in response to the blown fuse.
[0015] In certain embodiments the fault to be detected is a residual current fault and the test means includes a test switch (TS) having normally-open contacts (SW 3 ) and which when closed divert a portion of the supply current through the detecting circuit to cause a differential current to flow in said detecting circuit, closure of said test switch contacts (SW 3 ) also connecting the charge storage device (C 3 ) to the supply to allow the charge storage device to charge up.
[0016] In other embodiments the fault to be detected is an arc fault and the test means includes a test switch (TS) having normally-open contacts (SW 3 ) and which when closed divert a portion of the supply current to power a test signal generating circuit ( 50 ) which causes said differential current to flow in said detecting circuit, closure of said test switch contacts (SW 3 ) also connecting the charge storage device (C 3 ) to the supply to allow the charge storage device to charge up.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0017] Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0018] FIGS. 1 to 6 are circuit diagrams of first to sixth embodiments of the invention based on RCD circuits.
[0019] FIG. 7 is a circuit diagram of a seventh embodiment of the invention based on an AFD circuit.
DETAILED DESCRIPTION
[0020] In the various figures of the drawings the same references have been used for the same or equivalent components.
[0021] RCDs may be electrically latching (EL types) or mechanically latching (ML types), and the invention is applicable to both types.
[0022] FIG. 1 shows an embodiment of the invention based upon the electrically latching (EL type) RCD circuit described in Patent Application PCT/EP2012/050911, which is incorporated herein by reference in its entirety.
[0023] In FIG. 1 , an AC mains supply comprising live and neutral conductors L, N is connected to a load LD via normally-open load contacts SW 1 controlled by an electromechanical relay RLA. The circuit is supplied with power via a bridge rectifier X 1 , and the relay is supplied with a DC current. The RCD circuit is built around an RCD integrated circuit (IC) 100 , which may be a type WA050 supplied by Western Automation Research & Development and described in U.S. Pat. No. 7,068,047, which is incorporated herein by reference in its entirety. The IC 100 is supplied with current via a resistor R 2 .
[0024] The relay RLA is known as an electrically latching relay because it needs a constant current flow through its coil to maintain the contacts SW 1 in the closed position. Thus, when a current of sufficient magnitude (known as the closing current) is passed through the coil the resultant magnetic flux causes the load contacts SW 1 to close. Thereafter, the load contacts will remain closed provided a minimum holding current, less than the closing current, continues to flow through the relay coil. However, should the current flowing in the relay coil fall below the holding current the load contacts SW 1 will automatically open and can then only be re-closed manually (if a manual reset, not shown, is provided) or by increasing the magnitude of the current through the relay at least to the closing current. This relay design is simple and well proven.
[0025] The live and neutral conductors L, N pass through the toroidal core 20 of a current transformer CT en route to the load. The output of the current transformer, which appears across a secondary winding W 1 , is fed to the IC 100 . In the absence of a ground fault (residual) current, the vector sum of the currents flowing through the core 20 will be zero since the currents flowing in the L and N supply conductors will be equal and opposite; thus the voltage developed across W 1 will be zero. The function of the CT and IC 100 is to detect a differential current (i.e. a non-zero vector sum of currents) flowing through the CT core 20 having sufficient magnitude and/or duration as to be indicative of a residual current, and when such a differential current is detected to provide a high output voltage on line 10 sufficient to turn on a silicon controlled rectifier SCR 1 .
[0026] In FIG. 1 a resistor R 1 and a diode D 1 provide current to the relay RLA via a bridge rectifier X 1 . A capacitor C 1 smoothes the voltage across the relay RLA to prevent chatter. A Zener diode ZD 1 limits the voltage to a specified maximum level. For supply voltages at or above a minimum operating voltage of the RCD, C 1 will acquire a charge which will be at or above a voltage sufficient to provide a holding current through the relay RLA but insufficient to provide a closing current through the relay RLA.
[0027] Thus, a current of sufficient magnitude will flow continuously through RLA coil to enable the contacts SW 1 to remain closed once they have closed. A capacitor C 2 will acquire a charge via a resistor R 3 , and for supply voltages at or above the minimum operating voltage of the RCD, C 2 will acquire a charge which will be at or above a voltage sufficient to provide a closing current through the relay RLA, although clamped by a Zener diode ZD 2 at a safe level. The charge on C 2 is supplied via the resistor R 3 , but this current flow is limited to a relatively low value so as to minimise power dissipation in R 3 . When a reset button MR is closed by manual means, the voltage on C 2 will be applied to the RLA coil and the momentary application of this higher voltage will cause the relay RLA to close its contacts SW 1 . The voltage applied from C 2 will quickly collapse but RLA will be held in the closed state by the holding current supplied via R 1 and C 1 .
[0028] In the event of a residual current fault, as evidenced by an output on line 10 of the IC 100 , the SCR 1 will be turned on and effectively short out the coil of the relay RLA.
[0029] The resultant collapse in RLA voltage will cause the load contacts SW 1 to open and remove power to the load LD. The SCR 1 will turn off and C 1 will charge up to its previous voltage again but RLA will not automatically reclose until the reset button MR is closed again.
[0030] The RCD also includes a test switch comprising a manually operable test button TS which, when pressed, bridges normally-open contacts SW 3 . Pressing the test button TS diverts a portion of the supply current through a winding W 2 on the core 20 , via a resistor Rt. The current diverted through the core 20 will produce a differential current (i.e. a non-zero vector sum of currents) flowing through the CT core 20 , and the magnitude of the diverted current is selected such that the differential current so produced simulates a residual current. Accordingly, provided the RCD is operating correctly, the CT winding W 1 will produce an output which will be detected by the IC 100 which will, in turn, produce an output 10 to turn on SCR 1 and effectively short out the relay coil just as in the case of an actual residual current. Windings W 1 and W 2 may be separate windings or formed from a bifilar winding.
[0031] The embodiment of FIG. 1 further includes circuitry to disable the RCD in the event of the RCD failing to trip (i.e. the contacts SW 1 failing to open) on operation of the test button TS. Such circuitry comprises the components resistors R 4 and R 5 , capacitor C 3 , silicon controlled rectifier SCR 2 and a solenoid SOL having normally-closed contacts SW 2 in series with the relay RLA. Whereas the relay RLA is electrically latching and its contacts SW 1 are only closed when a holding current is flowing through its coil, the solenoid SOL is mechanically latched and its contacts will open when a current is passed through its coil (SOL could alternatively be a permanent magnet relay (PMR) which is held closed by a permanent magnet and opens when a current is passed through the PMR, or any convenient switching means intended to cause permanent removal of the supply from the load).
[0032] When the test button TS is operated, the RCD will normally trip (i.e. the contacts SW 1 will normally open) within about 40 mS. During this period a current will flow through the closed test switch and the resistor R 4 to charge up the capacitor C 3 . If the RCD trips in response to operation of the test button within its specified time, the current flow to C 3 will cease. However, if the RCD fails to trip on operation of the test button, the capacitor C 3 will continue to charge and eventually, after a certain time longer than the normal response time of the RCD, the voltage on the capacitor C 3 will rise to a level sufficient to turn on SCR 2 via resistor R 5 . At this point capacitor C 3 will discharge through the solenoid SOL. Activation of SOL will cause its normally closed contacts SW 2 to open and remove the supply to RLA, causing its contacts SW 1 to open in turn and remove power from the protected load LD. Preferably the RCD will be disabled with this arrangement to the extent that the RCD would need to be repaired or corrected before it could be successfully tested and operate normally again. More usually, however, the RCD would simply be replaced. A bleed resistor (not shown) may be placed across C 3 to ensure its discharge after each operation of the test circuit.
[0033] Instead of a silicon controlled rectifier, the solid state switch SCR 1 and/or SCR 2 may be a bipolar transistor, MOSFET or other solid state device which changes between high and low impedance states under the control of a signal applied at a control terminal.
[0034] FIG. 2 shows a second embodiment of the invention which is similar to that of FIG. 1 except that SOL and its contacts SW 2 have been replaced by a fuse F 1 in series with the relay RLA and which is suitably rated for normal operation of the RCD circuit. If the RCD fails to trip on operation of the test button TS, capacitor C 3 will charge up as before and cause SCR 2 to turn on after a certain period of time, and the resultant current flow via resistor R 6 , SCR 2 and fuse F 1 will cause the fuse to blow due to the excessive current flow through it. The relay RLA will therefore de-energise and its contacts SW 1 will open as before, and the RCD will be disabled.
[0035] The arrangement of FIG. 2 ensures end of life operation of the RCD in the event of failure of any of the key components including but not necessarily limited to X 1 , CT, Rt, WA050, TR 1 , R 2 , etc.
[0036] FIG. 3 is a circuit diagram showing a simplified version of a mechanically latched (ML type) RCD circuit embodying the invention. In this case the load contacts SW 1 are normally mechanically latched closed but can be opened by a sufficient current flowing through an associated solenoid SOL 1 . As in the previous embodiments, if there is a differential current flowing through the CT core having a magnitude and/or duration characteristic of a residual current, whether produced by an actual residual current or by the test circuit on pressing the test button TS, the IC 100 will produce an output 10 which will turn on the SCR 1 . This will allow supply current to flow through a solenoid SOL 1 which will open its mechanically latched contacts SW 1 and remove power to the load LD.
[0037] SOL 1 typically comprises a plunger which is biased towards a first position by a spring and which is moved to a second position during energisation of the solenoid so as to cause the load contacts to open, the plunger reverting to the first position on de-energisation of the solenoid and thereby facilitating manual reclosing of the contacts SW 1 .
[0038] The embodiment of FIG. 3 further includes circuitry to disable the RCD if the RCD contacts SW 1 fail to open when the test button TS is operated. Such circuitry comprises diode D 2 , resistors R 2 and R 3 , capacitor C 1 , silicon controlled rectifier SCR 2 and solenoid SOL 2 . The solenoid SOL 2 is coupled to the same mechanically latched load contacts SW 1 as the solenoid SOL 1 .
[0039] When the test button TS is operated, the RCD contacts SW 1 will normally open within about 40 mS. During this period a current will flow through the closed test switch and D 2 and R 2 to charge up the capacitor C 1 . If the RCD trips in response to operation of the test button within its specified time, the current flow to C 1 will cease. However, if the RCD fails to trip on operation of the test button, the capacitor C 1 will continue to charge and eventually, after a certain time longer than the normal response time of the RCD, the voltage on the capacitor C 1 will rise to a level sufficient to turn on SCR 2 via resistor R 3 . This will allow supply current to flow through the solenoid SOL 2 which will open the mechanically latched contacts SW 1 and remove power to the load LD.
[0040] In this case the plunger in SOL 2 may be a latching type which when moved from its first position to a second position remains in the second position so as to prevent manual reclosing of the contacts, and in this way prevent restoration of supply to the protected circuit. A bleed resistor (not shown) may be placed across C 1 to ensure its discharge after each operation of the test circuit.
[0041] A permanent magnet relay (PMR) would also be suitable for this application, as shown in FIG. 4 . In the arrangement of FIG. 4 , a permanent magnet relay (PMR) is used instead of the solenoid SOL 2 . When the voltage on C 1 reaches a certain level SCR 2 will turn on and cause C 1 to discharge through the PMR which is turn will cause the contacts SW 1 to open. The user will not have access to the PMR and it will not be possible to reset it and to reclose the contacts. The PMR has the advantage over the solenoid arrangement of being isolated from the mains supply which reduces the risk of SCR 2 being inadvertently turned on, for example by voltage spikes on the mains supply.
[0042] Provision could be made to facilitate resetting of SOL 2 or the PMR by removing the RCD from its installation and manually resetting the SOL or PMR opening means, for example by providing access from the back or the side of the RCD. However, this facility would preferably not be available to the user once the RCD has been installed and would only be intended for use by an experienced installer. If the SOL or PMR was reset, the RCD could be reinstalled, reclosed as normal and tested again by operation of the test button. Failure to trip as intended would again result in disabling of the RCD.
[0043] FIG. 5 shows another embodiment of an ML RCD, which uses a fuse to disable the RCD.
[0044] In the arrangement of FIG. 5 there is an end of life circuit comprising the components solenoid SOL 2 , diode D 3 , resistor R 4 , silicon controlled rectifier SCR 3 and fuse F 1 . SCR 3 is held in a non-conducting state because its gate is tied firmly to ground by fuse F 1 . If the RCD fails to open on operation of the test button, C 1 will charge up and cause SCR 2 to turn on, as previously described. The resultant current flow through R 5 , SCR 2 and F 1 will cause fuse F 1 to blow (the term “blow” includes the case of, for example, a PTC device going high impedance). SCR 3 will be turned on by R 4 pulling its gate high, at which stage supply current will flow through SOL 2 , causing the RCD contacts SW 1 (which are connected in common to SOL 1 and SOL 2 , as before) to open. Each time the RCD is subsequently reset it will autotrip if a conventional fuse is used for F 1 . If a PTC device is used, it will revert to its original low impedance when it has cooled down, but on subsequent operation of the test button it will force the RCD to trip as previously described.
[0045] The arrangement of FIG. 5 ensures end of life operation of the RCD in the event of failure of any of the key components including but not necessarily limited to, D 1 , CT, Rt, SOL 1 , R 1 , IC, SCR 1 , etc.
[0046] An LED with a current limiting resistor may advantageously be placed in parallel with F 1 or SOL 2 . This LED will light up momentarily when SCR 3 turns on, thus providing indication of an end of life operation.
[0047] The solenoids SOL 1 and SOL 2 in FIG. 5 could be combined such that the combination comprises of a single solenoid device with two windings, SOL 1 and SOL 2 . Winding SOL 2 would only be operated by SCR 3 in the event of failure of the RCD to open on operation of the test button. Likewise with FIG. 4 , a single PMR could be used instead of a solenoid and a PMR.
[0048] FIG. 6 shows an alternative version of FIG. 5 . In the arrangement of FIG. 6 , a single solenoid SOL 1 is used. This can be energised under normal conditions by SCR 1 , or under end of life conditions by SCR 3 , as previously described.
[0049] FIG. 7 shows an embodiment of the invention based upon the arc fault detector (AFD) circuit described with respect to FIG. 8 of Patent Application PCT/EP2011/058754, which is incorporated herein by reference in its entirety.
[0050] A single phase AC mains supply to a load LD comprises live L and neutral N conductors. In the absence of an arc fault condition, the full load current will flow in the conductors. A series or parallel arc fault condition will result in an arcing current flow in the circuit with a broad spectrum of frequencies.
[0051] In this embodiment, for the detection of arc faults a current transformer CT has a core 20 which surrounds just one of the supply conductors, in this case the neutral conductor N. The design of the CT is such that it has minimal response to slowly rising or sustained load currents at the mains supply frequency but is highly responsive to current pulses with very fast rise times which would be generated by arcing.
[0052] Arc fault current pulses in the neutral conductor N induce voltage spikes across the secondary winding W 1 . When these are above a certain threshold the IC 100 , here configured as an arc detector, will produce an output to an actuator 40 . In response, the actuator 40 opens associated load contacts SW 1 to disconnect the mains supply from the load LD. The details of the actuator 40 are not shown, but the actuator 40 may include a relay, solenoid or PMR, together with associated circuitry, as described for previous embodiments. In the present case it will be assumed that the actuator 40 includes a solenoid SOL 1 arranged as shown and described with reference to FIG. 6 .
[0053] When a test button TS is operated a test signal generator 50 is powered up from the mains supply and produces a series of pulses which will flow through a further winding W 2 on the CT core 20 . These pulses are designed to produce a differential current in the CT having characteristics which simulate the differential current produced by an actual arc fault (actually, due to the neutral conductor N passing though the core 20 , there will always be a non-zero vector sum of currents flowing through the CT, but the characteristics of the detection circuitry are designed not to respond to it). These pulses will be detected by the winding W 1 and fed to the IC 100 and cause the actuator 40 to open the load contacts SW 1 as before, typically within about 50 mS. The contacts can be reclosed by manual operation.
[0054] FIG. 7 also includes an “end of life” circuit comprising diode D 2 , resistors R 2 , R 3 , R 4 and R 5 , capacitor C 3 , silicon controlled rectifiers SCR 2 and SCR 3 , and fuse F 1 . These operate in the same way as the like referenced components in the end of life circuit of FIG. 5 .
[0055] When the test button TS is pressed to bridge the contacts SW 3 , capacitor C 1 will start to charge up via R 2 and D 2 . However, the AFD would normally trip (i.e. load contacts SW 1 open) within a certain time, e.g. 50 mS, in which case power would be removed from the circuit and all activity would cease. However in the event of the AFD failing to trip within the allotted time, C 1 would continue to charge up, and after a certain period, e.g. 200 mS, the voltage on C 1 would rise to a value sufficient to turn on SCR 2 via R 3 . Once SCR 2 turns on a relatively large current will flow via R 5 through SCR 2 and fuse F 1 . This current will be well in excess of the rating of the fuse F 1 so as to cause it to blow. When F 1 blows SCR 3 gate will be pulled high by R 4 which will cause SCR 3 to turn on and activate the solenoid SOL 1 in the actuator 40 . On each subsequent occasion when the AFD load contacts SW 1 are manually closed, the device will automatically trip because of SCR 3 being turned on and it will no longer be possible to use the AFD, thus indicating that it has reached the end of life state.
[0056] The invention is not limited to the embodiments described herein which may be modified or varied without departing from the scope of the invention. | A device for detecting a fault in an AC supply comprises a circuit (CT, 100 ) for detecting a particular type of fault in an AC supply to a load (LD) and providing a corresponding output ( 10 ). A relay (RLA) is responsive to said output ( 10 ) to open a set of load contacts (SW 1 ) in the AC supply to disconnect the load from the supply. Test means (TS, Rt, W 2 ) are provided for simulating a supply fault of the said type, and means (C 3, R 5, SCR 2, SOL, SW 2 ) are provided for causing the load contacts (SW 1 ) to open if they do not open in response to the simulated fault within a certain period of time. | 6 |
This application is a continuation of application Ser. No. 094,128, filed on 9/8/87, now abandoned.
DESCRIPTION
Technical Field
Sterols are alcohols used as starting materials in the manufacture of steroids or intermediates to biologically active steroids. They are present partly as esters in for instance distillation residues or so called desodorisates.
Isolation of sterols from these sources has so far been achieved either by alkaline hydrolysis or transesterification. A review has recently been published by A. Struwe et al in Fette, Seifen, Anstrichmitteln, 87, 103-106 (1985) and in DE-A1-2,936,125.
Both these methods have disadvantages that show up in the purification of the sterols. Addition of inorganic salts, i.e., sodium salts, to accomplish the hydrolysis or transesterification according to earlier methods makes it difficult to carry out extraction, crystallization, or distillation.
The transesterification is carried out with large molar excess of alkanol, leading to costly handling as well as too large distillation units for the recovery of alcanols, as well as to fire hazards, explosion risks, and environmental problems.
Thus a more simple and more rational process is desired.
An object of the present invention is to obtain a simple and rational process for the preparation of sterols from the mixtures containing sterols, and/or sterol derivatives so that they can readily be isolated by simple isolation processes known per se.
DESCRIPTION OF THE PRESENT INVENTION
It has now surprisingly turned out to be possible to overcome these difficulties by treating material that contains esters of sterols with ammonia, or different amines or compounds that liberate ammonia or amines when heated, e.g. urea. The method is thereby characterized by treatment of a product containing sterol esters with substantially equimolar amounts of ammonia and/or amine in relation to esters and acids present in the product, preferably at elevated temperature, and under elevated pressure.
By this method we obtain free sterols and amides of acids present. The free sterols can be isolated from the mixtures obtained by known methods. Suitable, but for the invention non-restricting raw materials containing sterols are different so called desodorisates, for instance, from soya, tall oil pitch, wool fat, some animal fats, gallic acids, coco oil, palm oil, tallow oil, where the sterols are present in concentrations of 1% or more.
Interesting sterols are, for example, stigmasterol, beta-sitosterol, campesterol, beta-sitostanol, cholesterol, and others.
Ammonia and different amines are, for example, primary, secondary, aliphatic, aromatic, araliphatic, cyclic, mono-, di-, tri-, or polyamines, as well as substituted amines can be used as well as compounds that liberate ammonia or amines at an elevated temperature, such as urea. Industrially ammonia, fatty amines or ethanol amines should be preferred.
The reaction is advantageously carried out at temperatures, where decomposition or rearrangement of the sterols is avoided, a temperature between about 100° C. and 250° C. is preferred. If the temperature is increased further, one has to check that the sterols are not damaged. The reaction can proceed with or without pressure. A solvent is generally not necessary. Water formed can, if needed, be removed under reduced pressure or by azeotropic distillation.
The reaction can be run batchwise or continuously.
The following amines are useful: primary amines such as methyl-, ethyl-, propyl-, butyl-, octyl-, 2-ethylhexylamine, lauryl-) tetradecyl-, cetyl-, octadecyl-, or fatty amines generally straight or with branched chains, cyclohexylamine, bensylamine, ethanolamine, propanolamine, aniline, substituted anilines, allylamine, hydroxyamine, etheramine as alcoxy propylamine.
Secondary amines are for example, dimethylamine, diethylamine, and so on with straight or branched chains being symmetric or asymmetric, morpholines, piperidines, diethanolamine, dicocoamine, secondary etheramines, or fatty acid alkylamines.
Diamines are, for example, hydrazine, ethylenediamines, laurylamineethylamine, piperazines. Triamines are diethylenetriamine, or polyamines.
Analysis method: The sample is treated with bis(trimethylsilyl) trifluoroacetamide and chlorotrimethyl silane in methylene chloride in a tube with a tight fitting at 70° C. for 30 minutes. The sample is then analyzed by gas chromatography in a capillary column SE-30, 25 m long, phase thickness 0.25 μm id 0.32 mm. Cholesterol (99.5%, Merck) was used as internal standard.
EXAMPLE 1
Water was removed from 1 kg soybean desodorisate by simple distillation. 400 g of the residue were treated with 120 g of laurylamine (dodecylamine) at 200° C. for 18 hrs. The reaction was chosen with respect to the completeness of the liberation of sterols, where also the sensitivity to temperature of the sterol must be taken in consideration. After purification, we isolated 27 g of a mixture of sterols, mainly containing beta-sotosterol, campesterol, stigmasterol. Total contents of sterols in the product was about 90%.
EXAMPLE 2
400 g of pitch from tallow distillation were treated with 33 g of hydrazine hydrate in a three-necked flask provided with a stirrer at 108° C. for 22 hrs after which time period about 75% of the sterols present were free. After purification 18 g of a mixture of mainly cholesterol, sitosterol, campesterol, and stigmasterol were obtained. The total content of sterols in the product was about 85%.
EXAMPLE 3
To 80 g of pitch from "tall" oil distillation residue 3 g of ammonia were added in an autoclave, and the temperature was increased to and maintained at 150° C. for 6 hrs. After purification 6 g of mixture of beta-sitosterol, campesterol, and sitostanol having a purity of totally 86% of sterols, were obtained.
EXAMPLE 4
In a continuous pressure reactor preheated "tall" oil pitch was charged at a rate of 100 g per hour simultaneously with ammonia at a rate of 8 g per hr. The temperature was 210° C. and the residence time was varied from 30 min to 3 hrs related to desired turnover. Ammonia could be recycled, thus allowing a larger excess. A mixture containing typically 11-14% of free sterols was obtained. The mixture could be further purified to give a crystalline product of 80-90% purity.
EXAMPLE 5
We treated 400 g of "tall" oil pitch with monoethanolamine in a three-necked flask provided with a stirrer at 160° C. After 12 hrs 90% of the sterols were free. After purification we isolated 32 g of a mixture of beta-sitosterol, campesterol and sitostanol having about 90% purity.
EXAMPLE 6
75 g of a residue from fatty acid recovery were treated with 13 g of aniline at 200° C. for 24 hrs. After purification we isolated 3.0 g of a mixture of sterols in 90% purity.
EXAMPLE 7
100 g of a residue from fatty acid recovery were treated with 20 g of diethanolamine in a three-necked flask provided with a stirrer. After 13 hrs at 170° C. we obtained a product that, after purification, gave 11 g of sterols of 86% purity.
EXAMPLE 8
Water was evaporated from 1 kg of soya desodorisate by a simple distillation. 400 g of the residue were treated with 110 g of "lilamuls PG" (N-tallowpropylene diamine) at 170° C. for 18 hrs. The reaction time is chosen in relation to the desired percentage of sterols to set free. After purification we isolated a mixture of 27 g of sterols, mainly consisting of beta-sitosterol, campesterol, stigmasterol in totally 90% purity.
EXAMPLE 9
To 120 g of pitch from "tall" oil distillation were added 13 g of urea in an autoclave, and the temperature was increased to and maintained at 270° C. for 5 hrs. After purification 15.5 g of a mixture of beta-sitosterol, campesterol and sitostanol having a purity of total 82% of sterols were obtained. | The present invention relates to a method to set free sterols from organic materials containing esters of such sterols, generally enriched distillation residues, or desodorisates by treating said organic material with ammonia and/or an amine and/or compound releases ammonia and/or amines while heated, the treament being carried out preferably at an elevated temperature, and under an elevated pressure. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to image processing in infrared cameras.
BACKGROUND
[0002] It is becoming more common to use various kinds of non-contact measurement equipment such as infrared cameras or pyrometers in order to measure the absolute temperatures or temperature differences on objects. The advantages of using an infrared camera are many. One of the most obvious is that the user will get a quick and complete temperature measurement of an object, and that the user could cover a more extensive area than is possible for most of the other means of measurement, like non-contact pyrometers or direct contact temperature devices such as platinum resistance thermometers, thermocouples or thermistors. For example, a user of a pyrometer will have to point the aperture of the pyrometer in lots of different directions trying to cover the area of interest; or if direct contact temperature devices are used, place them at specific points. Although many of these methods in certain situations have advantages over the use of infrared cameras, the risk of leaving an essential part undetected could never be completely avoided.
[0003] Infrared cameras are used today in a plurality of applications. An example is monitoring and controlling various technical systems, where the infrared cameras can help in detecting overheated system components like reactors, fans, valves, dynamos, transformers or other essential parts. The detection could also concern situations where frozen components or parts could lead to a risk of malfunction. Since significant information about the condition of a technical system can be given by measuring the temperatures, the use of infrared cameras is an easy and reliable way of identifying problems before a failure occurs due to stress in such a system.
[0004] Infrared cameras in related art typically utilise predefined parameterised functions implemented at a plurality of platforms. Examples of such platforms could be the infrared cameras themselves or other programmable devices related to the cameras like the software of a computer. The radiation captured and stored by the infrared camera is used together with these predefined functions to perform e.g. a temperature measurement or alarm analysis of the captured infrared radiation. An example of such a measuring function is the use of programmable coefficients or parameters accounting for the emissivity and reflectivity of the material of an object necessary for reliable temperature measurements of the object. An example of an alarm function could be one that triggers an alarm when at least one pixel value exceeds a defined temperature threshold value of the image. This could either activate a small internal alarm to alert the camera operator, or be used as a stationary monitoring device sending the alarm signal to a major warning system which comprises of light and sound sirens, for example in industries handling explosive chemicals. Other examples of predefined functions are readouts of maximum, minimum or average temperature values in an image, or readings concerning the temperature of particular spots or especially interesting areas. Isotherms (regions of an image having the same temperature) could also be emphasized by highlighting those regions with some sort of indication (e.g. colour, line); furthermore, the information in each pixel could be retrieved and used in analysis by standard programs.
[0005] A problem in having to implement these parameterised functions in advance arises when new or more advanced functions are needed or asked for by customers. The functionality of these predefined functions is fixed and realizing new or updated versions in order to change the functionality is both inefficient and cumbersome, since they must be implemented in advance at each of the platforms. In related art such an update is often related to a product release, in which case a user may have to wait for a long period of time. If the requirements change during the time period, the update may even be obsolete when it is released. The requirements may also differ between customers, in which case the customer might have to reduce his or her desires. This inherent lack of flexibility urges the need of a more adaptable concept.
SUMMARY
[0006] It is therefore an object of the present invention to provide a method and an apparatus to achieve a more flexible concept without having to implement the functionality in advance.
[0007] The invention relates to a method for processing information in images comprising the steps of receiving radiation from at least one object in an area; extracting radiometric information from the radiation; transforming the radiometric information into at least one digital image file; storing the at least one digital image file and at least one digital function file comprising an executable code characterised by the steps of merging the executable code of the at least one digital function file into or with the at least one digital image file, thereby generating an executable digital image file, wherein the executable code comprises at least one instruction and is written in a programming language independent of system architecture.
[0008] The invention also relates to an apparatus for processing information in images comprising a lens assembly arranged to receive radiation; a detector array for extracting radiometric information from the radiation; a processing unit arranged to transform and process the radiometric information into at least one digital image file; a memory storage providing means for storing the at least one digital image file and at least one digital function file comprising an executable code characterised in that the processing unit comprises a central processing unit which is arranged to merge the executable code of the at least one digital function file into the at least one digital image file, thereby generating an executable digital image file, wherein the executable code comprises at least one instruction and is written in a programming language independent of system architecture.
[0009] The invention further relates to a computer program product for use in central processing unit in a processing unit of an apparatus for processing information in images, which comprises computer readable code means, which when run in the central processing unit causes said central processing unit to perform the steps of merging an executable code of at least one digital function file into or with the at least one digital image file, thereby generating an executable digital image file, wherein the executable code comprises at least one instruction and is written in a programming language independent of system architecture.
[0010] Hence, the invention relates to a method and an apparatus for processing information in image files where the functionality will be accessible directly from within the executable digital image files themselves and exists in association with the file. Further, a cross-platform compatibility of the executable digital image file is achieved, or in other words, the executable digital image file can be executed independently of system architecture or platforms (i.e. software/hardware architectures) and transferred between and through different interfaces of such systems (e.g. computer/camera).
[0011] Further the invention relates to a method and an apparatus for executing the at least one instruction in order to use the radiometric information in the executable digital image file and to implement and retrieve functionality within the executable digital image file, where the instructions typically use the radiometric information in alarm and/or measurement functions. New functions can easily be implemented to fit different environments and situations. Another advantage is that the functions could be retrieved from within the files independently of system architecture.
[0012] The method and apparatus also make it possible to perform an interactive comparing analysis of the information comprised in at least two separate executable digital images files, creating the opportunity to validate aberrations in a structured and reliable way. By this any abbreviation between any two images, e.g. taken in the same location but at different time occasions, will be dealt with systematically.
[0013] With the method and apparatus it is also possible to retrieve at least one digital function file comprising the executable code, and in one embodiment of the present invention even to link the executable code of the at least one digital function file with the at least one digital image file instead of merging these entities with each other.
[0014] By the method and apparatus it is also possible to generate the at least one instruction comprised in the executable code by the means of at least one of the plurality of the control devices. Here a user can program the functionality he wants to achieve with a great degree of liberty.
[0015] Further advantageous embodiments of the apparatus, the method and the computer program product are set forth in the dependent claims, which correspondently describe further advantageous embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows an infrared camera according to the invention.
[0017] FIG. 2 shows an infrared camera attached to an external device.
[0018] FIG. 3 shows an image file according to the invention.
[0019] FIG. 4 shows a block diagram of a method for processing information according to an embodiment of the invention.
[0020] FIG. 5 shows a block diagram of a method for processing information according to another embodiment of the invention.
DETAILED DESCRIPTION
[0021] In FIG. 1 , an infrared camera 1 according an embodiment of the invention is shown. The infrared camera 1 comprises three main parts, a lens assembly 10 at one end for capturing radiation and at the other end an assembly 110 which may comprise a plurality of control devices 120 and at least one interface medium 130 . The plurality of control devices 120 could for example be a display, record/push-buttons and thumb-joysticks for programming, parameter settings and menu selection from a display, respectively. The at least one interface medium 130 could comprise removable SD-memory cards (secure digital cards), wire- or wireless communications means like USB (universal serial bus), Fire-Wire standards and IrDA (Infrared Data Association) or other short distance communication standards. Between these ends lays a main body 20 which may comprise a plurality of sub-assemblies or parts (e.g. processing unit, memory, A/D-converter, infrared detector array, etc.).
[0022] After the radiation emitted from an object 4 reaches the lens assembly 10 , which could comprise of one or more high quality lenses, it is focused and directed towards a detector array 30 in an appropriate manner. The detector array 30 , preferably an infrared detector array (for example a cooled or uncooled focal plane array), comprises individual sensors or pixels, which are sensitive to a range of the infrared radiation spectrum. The detector array 30 transforms the radiation into electrical analogue signals. This information of the radiation, which at present may be in the form of electrical analogue signals, is then further transformed into digital information, e.g. a digital image file 35 , by a processing unit 40 . The processing unit 40 may typically comprise a central processing unit (CPU) 50 , an analogue-to-digital (A/D) converter and other processing circuitry (not shown). Thus, the radiation information is captured by the IR camera 1 , and in all essence interpreted in a digital file format as a temperature measurement of the object 4 .
[0023] Furthermore, the digital image file 35 may then be registered and further processed by the central processing unit (CPU) 50 comprised in the processing unit 40 . The processing unit 40 and the central processing unit (CPU) 50 may be arranged to communicate with and have access to all parts of a memory storage 60 . This may, for example, be performed through a data communication port 100 in the memory storage 60 . The processing unit 40 may also be connected to at least one of the plurality of control devices 120 .
[0024] In order to achieve reliable and comparable measurements, the captured infrared radiation is taken in comparison with some additional information which may comprise calibration constants, camera and accessories settings, registration for background radiation, as well as destructive and non-destructive data (e.g. a compressed data format like JPEG and an uncompressed raw format, like PNG, respectively). Other types of data are also possible. This additional data may be stored in a file parameter/setting storage section 70 .
[0025] Once the information of the radiation is captured in the digital image file 35 and then processed by the processing unit 40 , using any or all information contained in the file parameter/setting storage section 70 , the digital image file 35 may be stored in a digital image file storage section 80 . The processing unit 40 may be arranged to retrieve the digital image file 35 from the digital image file storage section 80 at any point in time.
[0026] The processing unit 120 may be arranged to communicate with and be connected to the parameter/setting storage section 70 , the digital image file storage section 80 , the transmitting/receiving file storage section 90 and at least one of the plurality of control devices 120 by using, for example, the data communications port 100 .
[0027] In FIG. 2 , the infrared camera 1 and an external device 150 are shown. The external device 150 may be any sort of external memory storage device. Some examples of such external memory storage devices are a computer, a server at an internet address, another infrared camera, a CD (compact disc), memory stick (USB, SD), etc. From the external device 150 , a set of digital function files 140 , or file functions, comprising at least one digital function file 145 (but more generally the set comprises a plurality of digital function files, or file functions), may be selected.
[0028] The digital function files or file functions 140 comprised in the external device 150 may be communicated to the IR camera 1 by, for example, means of the interface medium 130 . The digital function files or file functions 140 may be placed in the transmitting/receiving file storage section 90 of the memory storage 60 . This could, for example, be realized by a downloadable package comprising the digital function files 140 . The at least one digital function file 145 may comprise an executable code 37 which may be arranged to be merged with the digital image file 35 contained in the digital image file storage section 80 .
[0029] According to one embodiment of the invention it is also possible for the memory storage 60 and/or the transmitting/receiving file storage section 90 to comprise at least one digital function file 145 before any communication with an external device 150 is performed by the IR camera 1 .
[0030] FIG. 3 shows a digital image file 35 and a digital function file 145 (or file function) comprised in the processing unit 40 and being processed by the central processing unit (CPU) 50 . In one preferred embodiment of the invention, the digital image file 35 and the at least one digital function file 145 (or file function) may be communicated to or retrieved by the processing unit 40 together or in successive order from the memory storage 60 . The processing unit 40 may then be arranged to merge or embed the executable code 37 comprised in and carried by the digital function file 145 with the digital image file 35 in the central processing unit 50 (as indicated by the arrow in FIG. 3 ). This may generate an executable digital image file 39 , that is, a digital image file comprising executable code. After this transformation into an executable digital image file 39 , further steps could in turn be to perform actions in accordance with at least one instruction 38 (normally a collection of instructions) comprised in the executable code 37 . These instruction(s) 38 may be arranged to use and process the information (e.g. temperature/pixel data matrix) comprised in the digital image file 35 .
[0031] In another embodiment, the user could build the at least one instruction(s) 38 comprised in the executable code 37 by the use of at least one of the plurality of control devices 120 . During the construction of the at least one instruction 38 , which may be made possible by, for example, programming means in the processing unit 40 , this information could be presented in real time before the user of the IR camera 1 during programming. This may be performed by, for example, a display device (e.g. a view editor of the IR camera 1 ) comprised in the plurality of control devices 120 . The display device could, for example, have a touch sensitive display, or present the information according to the user's commands given to the processing unit 40 by e.g. thumb buttons, joysticks or a keyboard.
[0032] The at least one instruction 38 comprised in the executable digital image file 39 , which may originate from the executable code 37 of the digital function file 145 or may be programmed by the user directly into the IR camera 1 , are typically organized in such a way as to perform an action, such as, for example, a measurement or alarm function, a clearer presentation of results, etc. This may, for example, be performed in order to achieve an easier and more flexible interpretation of the information within the executable digital image file 39 .
[0033] The instructions 38 comprised in the executable code 37 may typically include a series of text files, such as, for example, implicit include files as well as the script and the include files of the user. The bytecode of the instructions 38 may subsequently be executed, for example, on an abstract machine (also known as a virtual machine or emulator). The abstract machine normally comprises instructions organized as an instruction library (e.g. a native function library) embedded in the host application and corresponding host processor. The implementation of these instructions (e.g. native and/or wrapper functions) are used in implementing the interfaces between the abstract machine and the platforms (e.g. the IR camera 1 and an external device 150 ) in order to make the operations on the host processor (for example, a CPU 50 in the IR camera 1 or a processor in the external device 150 ) semantically equivalent to the original instructions.
[0034] These instructions could also link or wrap existing functions in the host environment, for example a software application written in a different programming language (to be able to reuse developed application software). In order to glue the existing functions, in for example the application software, a piece of instructions or code (e.g. in the native functions) is combined with another piece of instruction/code (e.g. the software or hardware application) which determines how the latter one is executed.
[0035] The inventive concept realised by a machine independent language, implements a cross-platform compatibility of the compiled binary code of the executable digital image file 39 ; or in other words, since the hardware and operating system dependence is reduced, the executable digital image file 39 could be executed independently of system architecture or platforms (i.e. software/hardware architectures) and therefore be transferred between and through different interfaces of such systems.
[0036] In practice, the executable code 37 may be generated by interpreting languages (e.g. Pearl) or compiling languages (e.g. Pawn, Java, C, etc) which could either be compiled to machine independent code (i.e. bytecode or P-code; pseudo code) or machine dependent code (machine code).
[0037] Another possible field of use of at least two executable digital image files 39 , also in accordance of the invention, are an interactive comparing of an image with a reference image (which could have been taken at an earlier stage perhaps years ago), in order to establish a structured and reliable way of making a validation of any aberrations in the images.
[0038] In one embodiment of the present invention it is also possible to link the executable code 37 to the digital image file 35 such that in all the communications and use in and between interfaces, parts or devices, that constellation is supported in the different computer system architectures it may encounter. In this embodiment the executable code 37 comprising at least one instruction 38 is preferably carried by the digital function file 145 to the central processing unit 50 , whereby the executable code 37 may be linked with the digital image file 35 . After this process, which generates a digital image file linked to an executable code, a linked unit defined as an executable digital image file 39 is generated. Further steps could in turn be to perform actions in accordance with at least one instruction 38 (normally a collection of instructions) comprised in the executable code 37 upon the information comprised in the digital image file 35 . This may be carried out at once or later on, and if a plurality of instructions is concerned, one at a time, all together or in any combination thereof.
[0039] The executable digital image file 39 could be transferred and stored in the memory storage 60 , e.g. the digital image file storage section 80 or the transmitting/receiving file storage section 90 ; alternatively the executable digital image file 39 may be re-routed to any of the interfaces media 130 and stored in a removable memory device, or transferred to an external device 150 , where it may be stored or further processed.
[0040] In FIG. 4 , the steps for transforming the radiation from an object 4 to an executable digital image file 39 in an IR camera 1 according to an embodiment of the invention are shown.
[0041] In step S 41 , the radiation is received from an object 4 through the lens assembly 10 by a user aiming the IR camera 1 towards an area comprising at least one object of interest. In step S 42 , the radiometric information may be extracted from the radiation by the detector array 30 .
[0042] In step S 43 , the radiometric information may be transformed into at least one digital image file 35 . In step S 44 , the at least one digital image file 35 may be merged with the executable code 37 of at least one digital function file 145 in the central processing unit (CPU) 50 of the processing unit 40 . This will result in an executable digital image file 39 , which then may be stored in the memory storage 60 , analysed, transferred, and/or transformed to a different system architecture for further analysis.
[0043] In FIG. 5 , steps for creating an executable digital image file 39 according to an embodiment of the invention are shown.
[0044] In step S 51 , at least one digital file function 145 may be uploaded/downloaded to the memory storage 60 , for example, to the transmitting/receiving section 90 . This may, for example, be performed from an external device 150 and in the form of a downloadable package. The upload/download may be initiated by a user through the IR camera 1 or through the external device 150 .
[0045] In step S 52 , the central processing unit (CPU) 50 in the processing unit 40 may communicate with the memory storage 60 (or the transmitting/receiving section 90 ) in order to retrieve the at least one digital file function 145 .
[0046] In step S 53 , the executable code 37 of at least one digital function file 145 may be merged with at least one digital image file 35 in the central processing unit (CPU) 50 of the processing unit 40 . This will result in an executable digital image file 39 , which then may be stored in the memory storage 60 , analysed, transferred, and/or transformed to a different system architecture for further analysis.
[0047] The description above is of the best mode presently contemplated for practising the invention. The description is not intended to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be ascertained with reference to the issued claims. | The invention relates to a method and an apparatus for processing information in images pictured by infrared cameras comprising the steps of receiving radiation from at least one object in an area; extracting radiometric information from the radiation; transforming the radiometric information into at least one digital image file; storing the at least one digital image file and at least one digital function file comprising an executable code characterised by the steps of merging the executable code of the at least one digital function file into or with the at least one digital image file, thereby generating an executable digital image file, wherein the executable code comprises at least one instruction and is written in a programming language independent of system architecture. The invention further relates to a computer program product.
By this inventive concept is achieved a cross-platform compatibility of the executable digital images files that makes them independent of computer system architecture. New functions, like for example new alarm and measurement functions, are also easily implemented, retrieved and exchanged since the executable code, which governs the functionality, is accessible directly from within the executable digital image files themselves and exists in association with the file independent of to which system it has been transferred. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of, and claims priority to, U.S. Non-Provisional patent application Ser. No. 14/593,748 entitled “CONTAINER WITH MIXING BLADE” filed on Jan. 9, 2015; U.S. Non-Provisional patent application Ser. No. 14/593,763 entitled “CONTAINER WITH MIXING BLADE” filed on Jan. 9, 2015; U.S. Non-Provisional patent application Ser. No. 14/593,771 entitled “CONTAINER WITH MIXING BLADE” filed on Jan. 9, 2015; and U.S. Non-Provisional patent application Ser. No. 14/593,788 entitled “CONTAINER WITH MIXING BLADE” filed on Jan. 9, 2015, all of which are incorporated by reference herein for all purposes.
TECHNICAL FIELD
[0002] Disclosed herein is a method and system for separately storing and mixing two or more substances.
DESCRIPTION OF RELATED ART
[0003] There exist prior art systems for separately storing and mixing two or more substances. Examples include the systems described in U.S. Pat. Nos. 6,059,443, 7,861,855 B2, 8,720,680 B2, and European Patent No. EP 2190751B1, the disclosures of which are incorporated by reference. Disclosed herein is an improved method and system for separately storing and mixing two or more substances.
SUMMARY OF THE DISCLOSURE
[0004] In one aspect, what is disclosed herein is a container system. The container system includes a mixing container having a main container that stores one or more first substances. The main container has a first upper opening. The container system also includes a storage repository coupled to main container, and which stores one or more second substances. The storage repository includes a lip defining a second upper opening, which has an outside diameter smaller than the diameter of the first upper opening. Additionally, the container system includes a mixing blade having an outside diameter smaller than the diameter of the first upper opening and an inside diameter smaller than the outside diameter of the storage repository's lip. The mixing blade also has a plurality of openings. Furthermore, the container system includes a releasable liner placed over the storage repository's lip, and the storage repository's lip forms a seal with a lower surface of the releasable liner.
[0005] In another aspect, presently disclosed is a method of separately storing one or more first substances and one or more second substances, and mixing the substances at the time of usage of a product comprising a mixture of the substances. The method involves agitating the container system after removal of the releasable liner so that the one or more first substances and one or more second substances are permitted to mix with another.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The disclosure will be better understood and its numerous objects and advantages will become more apparent to those skilled in the art by reference to the following drawings, in conjunction with the accompanying specification, in which:
[0007] FIG. 1 is an exploded perspective view of a preferred embodiment of the container system of the present disclosure;
[0008] FIG. 1A is an exploded perspective view of an alternative embodiment of the container system of the present disclosure;
[0009] FIG. 2 is a perspective view of a preferred embodiment of the container system of the present disclosure with the storage repository covered by a releasable liner;
[0010] FIG. 3 is a perspective view of a preferred embodiment of the container system of the present disclosure showing the releasable liner being released;
[0011] FIG. 4 is a view of the container system showing the container system being agitated so that the one or more first substances and one or more second substances are mixed;
[0012] FIG. 5 is an exploded, front elevational, cross-sectional view of a preferred embodiment of the container system of the present disclosure;
[0013] FIG. 6 is a front elevational, cross-sectional view of a preferred embodiment of the container system of the present disclosure with the releasable liner placed over the storage repository;
[0014] FIG. 7 is a front elevational, cross-sectional view of a preferred embodiment of the container system of the present disclosure with the releasable liner removed;
[0015] FIG. 8A is a top, or overhead, view of the storage repository of a preferred embodiment of the container system of the present disclosure;
[0016] FIG. 8B is a perspective view of the storage repository of a preferred embodiment of the container system of the present disclosure;
[0017] FIG. 9 is an exploded, front elevational, cross-sectional view of an alternative preferred embodiment of the container system of the present disclosure;
[0018] FIG. 10 is a front elevational, cross-sectional view of the alternative preferred embodiment of the container system of the present disclosure with the releasable liner placed over the storage repository;
[0019] FIG. 11 is a front elevational, cross-sectional view of the alternative preferred embodiment of the container system of the present disclosure with the releasable liner removed; and
[0020] FIG. 12 is a side, cross-sectional, perspective view of an alternative mixing blade coupled to the cap of the alternative preferred embodiment of the container system of the present disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
[0021] Referring to FIGS. 1-7 , a preferred storage and mixing container 10 comprises a bottle 100 for containing one or more first substances, such as a liquid 33 , a storage repository 17 for containing one or more second substances, such as a powder 35 . The storage repository 17 is disposed within an upper opening 110 of the bottle 100 and coupled to the neck 120 of the bottle 100 . This preferred embodiment includes a releasable liner 25 to cover a second upper opening 19 of the storage repository 17 when the container 10 is used to separately store the powder 35 from the liquid 33 , and a cap 300 including a mixing blade 200 that couples to the bottle 100 , such as by threads 14 .
[0022] As depicted in FIGS. 1-3 and FIGS. 5-6 , the cap 300 may comprise an element 200 , sometimes referred to as a mixing blade, which is generally centrally located within the interior of the cap 300 . As shown, the element 200 may be generally ring-shaped and have substantially the same diameter as the lip 18 defining an upper opening to the storage repository 17 . Further, the element 200 may comprise ports 210 through the walls thereof. One of ordinary skill in the art will appreciate element 200 can be implemented in shapes other than circular shapes, such as a square, rectangle, pentagon, and the like; if non-circular shapes are used for element 200 , lip 18 should be formed so that it generally matches the non-circular shape of and has the same perimeter as element 200 .
[0023] In various implementations, the element 200 may be formed integrally within the cap 300 , as shown in FIG. 1 , or the element 200 may be formed separately from the cap 300 and secured within a ring 310 disposed in cap 300 , as shown in FIG. 1A . In the implementation of FIG. 1A , the element 200 may be secured within the ring 310 via interference fit and/or otherwise coupled to the cap 300 adhesively, mechanically, magnetically or by other means that will be apparent to one of ordinary skill in the art.
[0024] As depicted in FIGS. 1 and 1A , the container system includes one or more couplings 400 used so that the storage repository 17 will be disposed within an upper opening of the bottle 100 and coupled to the neck 120 of the bottle 100 . Disposition of the storage repository 17 within the bottle 100 is depicted in FIGS. 6 and 7 .
[0025] As depicted in FIG. 6 , when the cap 300 is coupled to the bottle 100 while the releasable liner 25 is present, and the mixing blade 200 is contacting an upper surface of the releasable liner 25 , a seal is formed between a lower surface of the releasable liner 25 and the lip 18 of the storage repository 17 . The seal prevents the one or more first substances 33 from mixing with the one or more second substances 35 . As shown in FIG. 6 , the cap 300 is coupled to the bottle 100 using threads, but one of ordinary skill in the art will appreciate any number of other means can be used to couple cap 300 to bottle 100 .
[0026] FIG. 7 depicts the container system when the releasable liner 25 has been removed. A gap 37 is provided, comprising space above the one or more couplings, continuing above the upper opening 110 of the bottle 100 , and below an interior surface of the top of the cap 300 , through ports 210 , and into additional open space inside mixing blade 200 . The gap 37 provides additional space to facilitate mixing of liquid 33 and powder 35 . When releasable liner 25 has been removed, liquid 33 may move between the bottle 100 , gap 37 , and storage repository 17 by passing around the one or more couplings 400 and through the one or more ports 210 of the mixing blade 200 . Likewise, when releasable liner 25 has been removed, powder 35 , may move between the storage repository 17 , gap 37 , and the bottle 100 by passing through ports 210 of the mixing blade 200 and the one or more couplings 400 . Such mixing is depicted in FIG. 7 , and occurs when, for example, the bottle 100 is shaken, inverted, or otherwise agitated, one example of such agitation being depicted in FIG. 4 .
[0027] In a preferred embodiment, as depicted in FIGS. 6 and 7 , mixing blade 200 may have substantially the same height as the height of the space created between the upper opening 110 of the bottle 100 and the interior surface of the top of the cap 300 , and the diameter of the mixing blade may have substantially the same diameter as the diameter of the lip 18 of the storage repository 17 . One of ordinary skill in the art will appreciate that mixing blade 200 can be designed with ports 210 having virtually any shape, including polygonal shapes such as rectangles, squares, and triangles, or curved shapes, such as circles. Also, the number of ports 210 that may be used is not limited to the number depicted in FIGS. 1-3 .
[0028] While the one or more couplings 400 may not be designed so that the one or more first substances and one or more second substances are completely prevented from moving between the bottle 100 and storage repository 17 , one of ordinary skill in the art will appreciate that various couplings may be used to couple the storage repository 17 to the neck 110 of bottle 100 . Couplings 400 may consist of a single piece of material having ports through which the one or more first and second substances may move, or, as depicted in FIGS. 8A and 8B , multiple pieces of material, such as support arms 410 , that are placed apart from one another to create space 407 through which the one or more first and second substances may move. Also, couplings 400 may be manufactured as one piece with the storage repository 17 or bottle 100 , or may be separate components.
[0029] Referring to FIGS. 9-11 , wherein like reference numerals correspond to like components, another alternative preferred storage and mixing container 10 ′ is depicted comprising an alternative element 200 ′, sometimes referred to as an alternative mixing blade. The alternative element 200 ′ comprises one or more ports 210 ′ extending through the walls thereof. The alternative element 200 ′ further comprises a lower portion 230 that extends into a non-vertical wall portion 231 formed adjacent to the ports 210 ′ and providing a lower boundary to the ports 210 ′. As used herein, the term non-vertical means not perpendicular to the plane defined by upper opening 110 of the bottle 100 . One of ordinary skill in the art will appreciate that a non-vertical wall portion can be formed into a variety of linear or curved shapes, or a combination of different shapes.
[0030] The alternative element 200 ′ may be generally centrally located within the interior of the cap 300 of the alternative container 10 ′. Similar to element 200 shown in FIGS. 1-7 , the alternative element 200 ′ may be generally ring-shaped and have substantially the same diameter as the lip 18 defining an upper opening to the storage repository 17 . One of ordinary skill in the art will appreciate that the alternative element 200 ′ can be implemented in shapes other than circular shapes, such as a square, rectangle, pentagon, and the like; if non-circular shapes are used for alternative element 200 ′, then lip 18 of the alternative container 10 ′ should be formed so that it generally matches the non-circular shape of and has the same perimeter as alternative element 200 ′.
[0031] In various implementations, the alternative element 200 ′ may be formed integrally within the cap 300 , as shown in FIG. 1 , or the alternative element 200 ′ may be formed separately from the cap 300 and secured within a ring 310 disposed in the cap 300 , as shown in FIG. 1A . The alternative element 200 ′ may be secured within the ring 310 via interference fit and/or otherwise coupled to the cap 300 adhesively, mechanically, magnetically or by other means that will be apparent to one of ordinary skill in the art.
[0032] FIG. 12 depicts a side, cross-sectional, perspective view of the cap 300 with the alternative element 200 ′ coupled thereto. As depicted in FIG. 9-12 , each of the substantially vertical wall portion 230 and the non-vertical wall portion 231 of the alternative element 200 ′ comprises opposing sides. The opposing sides of the substantially vertical wall portion 230 may be substantially parallel to each other and substantially perpendicular to the lip 18 of the alternative container 10 ′. At least one of the opposing sides of the non-vertical wall portion 231 may be tapered so as to extend at an angle from the corresponding side of the substantially vertical wall portion 230 toward the other opposing side of the non-vertical wall portion 231 . If both opposing sides of the non-vertical wall portion 231 are tapered, they may extend toward each other at substantially the same angle or at different angles from the corresponding side of the substantially vertical wall portion 230 . As shown, the opposing sides of the non-vertical wall portion 231 may terminate substantially at a point adjacent to the ports 210 ′.
[0033] As depicted in FIG. 10 , when the cap 300 is coupled to the bottle 100 while the releasable liner 25 is present, and the mixing blade 200 ′ is contacting an upper surface of the releasable liner 25 , a seal is formed between a lower surface of the releasable liner 25 and the lip 18 of the storage repository 17 . The seal prevents the one or more first substances 33 from mixing with the one or more second substances 35 .
[0034] FIG. 11 depicts the container system when the releasable liner 25 has been removed. A gap 37 is provided, comprising space above the one or more couplings, continuing above the upper opening 110 of the bottle 100 , and below an interior surface of the top of the cap 300 , through ports 210 ′, and into additional open space inside alternative mixing blade 200 ′. The gap 37 provides additional space to facilitate mixing of liquid 33 and powder 35 . When releasable liner 25 has been removed, liquid 33 may move between the bottle 100 , gap 37 , and storage repository 17 by passing around the one or more couplings 400 and through ports 210 ′ of the alternative mixing blade 200 ′. Likewise, when releasable liner 25 has been removed, powder 35 may move between the storage repository 17 , gap 37 , and the bottle 100 by passing through ports 210 ′ of the alternative mixing blade 200 ′ and the one or more couplings 400 .
[0035] As shown in FIG. 11 , such mixing occurs when, for example, the bottle 100 is shaken, inverted, or otherwise agitated, one example of such agitation being depicted in FIG. 4 . During such mixing, the non-vertical surface 231 of the alternative mixing blade 200 ′ may inhibit or prevent the build-up of powder 35 , or any other second substance, on the alternative mixing blade 200 ′ and may further enhance mixing as powder 35 moves from the storage repository 17 and through the ports 210 ′ of the alternative mixing blade 200 ′.
[0036] As depicted in FIGS. 9-11 , the alternative mixing blade 200 ′ may have substantially the same height as the height of the space created between the upper opening 110 of the bottle 100 and the interior surface of the top of the cap 300 , and the diameter of the alternative mixing blade 200 ′ may have substantially the same diameter as the diameter of the lip 18 of the storage repository 17 . One of ordinary skill in the art will appreciate that the alternative mixing blade 200 ′ can be designed with ports 210 ′ having virtually any shape, including polygonal shapes such as rectangles, squares, and triangles, or curved shapes, such as circles. Also, the number of ports 210 ′ that may be used is not limited to the number depicted in FIGS. 1-12 .
[0037] The one or more first substances and the one or more second substances may each be in solid form, liquid form, or some combination thereof. Examples of substances that may be used in connection with the container system include but are not limited to the following substances: water, dehydrated substances, preservative free substances, dietary supplement mixtures, nutritional mixtures, protein mixtures, dairy based proteins, milk proteins, whey proteins, vegetable based proteins, soy based proteins, amino-acids, beta alanine, vitamins, minerals, creatine, glutamine, L-arginine, phenylalanine, L-Leucine, L-Isoleucine, L-yaline, Synephrine, yohimbe, ginseng, ascorbic acid, hydroxyl citric acid, aloe vera, dimethylamyamine, polysaccharide, monosaccharide, maltodextrin, dextrose, fructose, silicon, artificial sweeteners, natural sweeteners, sucralose, artificial or natural flavors, artificial or natural colors, tea, coffee, dairy product, or any other substances which may be consumed by a user either alone, or in combination with any other chemical or other substance.
[0038] The bottle 100 and storage repository 17 may be constructed of any material suitable for storing liquid or solid substances. In a preferred embodiment, the bottle 100 is manufactured of polyethylene terephthalate (PET). One of ordinary skill in the art will appreciate that other materials also could be used to manufacture said bottle 100 or storage repository 17 , such as other plastics (including High Density Polyethylene and polypropylene), glass, metal, styrofoam and the like. It is contemplated that alternate embodiments of the container system may be constructed of materials suitable for heating within a microwave oven or other heating apparatus. Cap 300 , mixing blade 200 , alternative mixing blade 200 ′, and the one or more couplings 400 may likewise be constructed of any suitable materials, including those identified above.
[0039] The purpose of releasable liner 25 is to prevent the mixing of the one or more first substances and the one or more second substances. One of ordinary skill in the art will therefore appreciate releasable liner 25 can be implemented in the container system of the present disclosure in many different ways. Releasable liner 25 may cover first upper opening 110 of the bottle 100 and the second upper opening 19 of storage repository 17 , but one of ordinary skill in the art will appreciate releasable liner 25 need only cover second upper opening 19 . Releasable liner 25 may be a gasket, i.e., it may be loosely placed over second upper opening 19 in the absence of cap 300 being placed on bottle 100 , so that the releasable liner 25 might fall off when cap 300 is removed. Or, releasable liner 25 might be coupled to bottle 100 and/or lip 18 using an adhesive. Releasable liner 25 could even be formed in the shape of a sphere, such as a marble, or a spherical cone, and be disposed in second upper opening 19 of storage repository 17 .
[0040] It is believed the operation and construction of the apparatus and method disclosed herein will be apparent from the foregoing description. While the apparatus and method shown and described has been characterized as being preferred, it will be readily apparent that various changes and modifications could be made without departing from the spirit and scope of the disclosure. | A container system for separately storing and mixing two or more substances. The container system comprises a mixing container having a main container that stores one or more first substances. The main container has a first upper opening. The container system also includes a storage repository coupled to main container, and which stores one or more second substances. The storage repository includes a lip defining a second upper opening, which has an outside diameter smaller than the diameter of the first upper opening. Additionally, the container system includes a mixing blade having an outside diameter smaller than the diameter of the first upper opening. The mixing blade also has a plurality of openings and a non-vertical wall portion adjacent said plurality of openings. The container system includes a releasable liner placed over the storage repository's lip, and the storage repository's lip forms a seal with a lower surface of the releasable liner. | 0 |
TECHNICAL FIELD
The present invention relates to the deconstruction that is to say the dismantling of flat screens.
BACKGROUND
It applies to any types of screen, whether it be screens with a liquid crystal panel (LCD Liquid Crystal Display) and backlight lamps (CCFL, LED or other) or other types of displays, such as:
Plasma
OLED (organic light emitting diode)
SED (Surface-conduction Electron-emitter Display)
FED (Field Emission Display)
OEL (Organic Electroluminescent)
PLED (polymer light-emitting diodes)
PHOLED (Phosphorescent Organic Light-Emitting Diode)
In order to destroy or decontaminate these flat screens at the end of life, there are industrial methods of at least partially grinding these screens during which the faceplate and/or the backlight lamps are usually destroyed or partially damaged. Hence, such methods can cause the release of gases and toxic substances, such as mercury, for example, in the air, on the ground, or in direct contact with constituents of the screen that are liable to be recycled. However, the mercury that is released tends to pollute the other screen members, such as plastic which becomes difficult to recycle. These methods are hence responsible for some pollution and substantially increase the difficulty of recovering any recoverable components, particularly liquid crystals, and metals, particularly indium from the screen.
At present, the existing solutions consist in crushing the screen and drawing out the toxic gaseous elements, or dismantling the screen entirely manually, which is not satisfactory in terms of environmental protection, and in terms of productivity.
BRIEF SUMMARY
The purpose of the present invention is to overcome these drawbacks by proposing a solution aiming to preserve the integrity of the faceplate of a flat screen as much as possible.
More specifically, the invention relates to a method of deconstructing at least partially a flat display screen, the screen comprising:
a substantially plane faceplate, comprising four lateral edges and an visible portion on a front side of the screen intended for image display, and
a frame, mounting the faceplate by partially covering at least the front side and two lateral edges,
the method comprising steps including:
placing a single screen on a holding device, and
clamping the single screen on the holding device.
According to the invention, the method is substantially characterized in that it further comprises a step including:
carrying out a plastic deformation of the frame, while maintaining the integrity of the faceplate.
Thanks to this characteristic, it is possible to avoid cutting the frame. This makes it possible to open the screen while avoiding aggressive industrial techniques and which generate waste (in particular non-recoverable). In particular, cutting leads to:
many vibrations in the screen (which can lead to the damage of fragile members such as mercury lamps)
generates a lot of dust, gas and chips, and
induces consumables (a cutting tool has a limited life).
In one embodiment, the method further comprises a step of weakening of the frame by mechanical action and/or heat on the frame.
Thus allowing to limit the forces to be applied for deforming the frame.
Preferably, the weakening step is only implemented on all or part of the portion of the frame which partially covers the front side of the screen.
In one embodiment, at least two out of the four corners of the screen are clamped, the plastic deformation being performed on an unclamped corner.
In one embodiment, the method further comprises a step of determining the dimensions and the position in space of the visible faceplate.
This then allows to subject the efforts to be applied to the determined dimensions.
In one embodiment, the method further comprises a step of laser profilometry including obtaining the three-dimensional topography of at least one portion of the screen.
Thus allowing for an optical tracking of the screen, that is to say, a shape analysis thereof.
In one embodiment, the method further comprises a step comprising removing the faceplate from the frame.
The invention further relates to a device for holding a flat display screen for at least its partial deconstruction, the device comprising:
a clamping system comprising:
a support, whereon a screen is likely to be positioned,
a set of independent branches mounted on the support,
a flange positioned at the end of each branch.
Preferably, each flange is rotatably mounted with respect to the branch which supports it, according to an axis of rotation perpendicular to the plane of the support, and/or each branch is mounted in rotation with respect to the support, according to an axis of rotation perpendicular to the plane of the support.
Advantageously, each branch is telescopic.
The invention is advantageously compatible with all screens, whatever their status (new or used), size (dimensions of the faceplate), their weight and their material(s) of manufacture.
The invention also relates to a system for at least the partial deconstruction of a flat display screen, the system comprising
a holding device according to the invention,
possibly a screen positioned in the holding device, and
a plastic deformation device liable to be set in relative motion with respect to the screen such as to exert a mechanical force on the frame in order to deform it according to at least one of the following trajectories: a rectilinear trajectory parallel with the plane of the faceplate, a rectilinear trajectory non parallel with the plane of the faceplate, a curved trajectory, or a combination of these movements.
Preferably, the plastic deformation device comprises
a knife and
possibly a rotating force transmission means, connected to the knife,
the knife comprising a form making it possible to concentrate the constraints to be applied to the frame.
Advantageously, the knife exhibits a leading edge that is configured to switch between the faceplate and the frame.
The knife may have a leading edge exhibiting a variable opening angle on the depth of the knife.
It can also be provided a camera to view on the console of an operator the proceedings of the application of the plastic deformation forces.
Thanks to the invention, it is possible to move aside at least one side of a screen by deforming the frame thereof, this makes it possible to remove the faceplate and any possible filters/diffusers, as well as give access to any possible backlight lamps.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the present invention will become apparent upon reading the following description given by way of illustrative and non-limiting example and with reference to the accompanying drawings in which:
FIG. 1 illustrates one embodiment of the method according to the invention, wherein the optional steps are in dotted lines,
FIG. 2A illustrates a front view of a flat screen,
FIG. 2B illustrates a front view of a flat screen with circular areas illustrating preferential areas of weakness of the frame,
FIG. 3 illustrates a flat screen maintained in an embodiment of a holding device according to the invention, in a three-quarter view,
FIG. 4A illustrates one embodiment of a knife according to the invention in top view,
FIG. 4A ′ illustrates the knife of FIG. 4A in side view,
FIG. 4B illustrates an embodiment of a knife according to the invention in three-quarter view,
FIG. 4B ′ illustrates the knife of FIG. 4B in side view,
FIG. 4C illustrates one embodiment of a knife according to the invention in top view,
FIG. 4C ′ illustrates the knife of FIG. 4C in three-quarter view,
FIGS. 5A to 5D illustrate in top view, by full arrows, the different knife movements for the deformation of the frame of a screen with a knife ( FIG. 5C ), two knives ( FIG. 5B ), three knives ( FIG. 5D ), and four knives ( FIG. 5A ),
FIGS. 6A to 6D illustrate in transversal cross-section by full arrows, different movements of translation and/or rotation for a knife, applied on the frame, the casing not being represented,
FIG. 7 illustrates in transversal cross section the result of plastic deformation by a knife on the frame of a flat screen, wherein the casing is not represented,
FIG. 8 illustrates in substantially top view the clamping of a screen in an embodiment of a holding device according to the invention, wherein the flanges do not cover the faceplate, the dots illustrating the limits of the faceplate concealed by the casing,
FIG. 9 illustrates an embodiment of a holding device according to the invention,
FIG. 10 illustrates by full arrows the possible movements of translation and rotation for an arm of an embodiment of a holding device according to the invention, and
FIG. 11 illustrates the holding of a screen on a support according to another embodiment of a holding device according to the invention.
DETAILED DESCRIPTION
These days, there are flat screens in many fields: computer monitors, televisions, tablet PCs, navigation devices, etc. For environmental reasons, it is desirable that all flat screens be deconstructed at the end of life, in order to make the treatment of their components possible, particularly their recovery.
All flat panel screens include a faceplate, which allows for the display on the front side of the screen.
By faceplate 11 or matrix, is meant the generally rectangular portion of a flat screen 10 whereon the image is formed. For an LCD screen 10 , the polluting elements are the liquid crystals enclosed between two fine glass plates and which allow for the formation of the image.
Certain flat screens comprise backlight lamps, placed behind the faceplate 11 with respect to the display. Some lamps may also contain polluting elements (for example, mercury).
The faceplate 11 is contained in a frame 13 .
The frame 13 is generally made of metal and has a function of maintaining the constitutive members of the screen, particularly the faceplate.
The faceplate 11 and the frame 13 are housed in a casing 14 .
The casing 14 is generally made of plastic, of globally parallelepiped shape and has a generally aesthetic function of concealing the structural members such as the frame 13 and/or the possible seals, connectors, etc. which would otherwise be apparent. It also covers the rear side of the screen.
The mechanical resistance of the frame 13 being greater than that of the casing 14 , the plastic deformation aimed for here relates to that of the frame, any plastic deformation of the frame 13 causing that of the casing 14 .
The casing 14 has a substantially rectangular opening (window) whereof the dimensions are slightly lower than the dimensions of the surface of the faceplate, such that the faceplate 11 has a visible portion, called “visible faceplate 12 ” ( FIG. 2A ), and a portion concealed under the casing. The casing 14 encloses the faceplate 11 by securely covering the edges thereof.
For the treatment of flat screens, with a view to their recovery, it is important to maintain the integrity at least of the faceplate, and possibly of the backlight lamps. Integrity is considered to be kept as long as the damage subjected to a screen 10 does not allow the release of polluting elements. In this vein, it can be considered for example that the faceplate 11 may be scratched.
The advantage of keeping the integrity is that the pollutant suction devices can be used only by way of precaution in the event of an accident for example, and not for every dismantling of each screen 10 as in the prior art.
Method
It can be provided a preliminary step of preparing the screen 10 , comprising removing the possible stand of the screen, removing possible cables or aesthetic elements (stickers, etc.).
It is provided a step 100 comprising arranging a single screen 10 on a holding device, preferably the visible faceplate 12 towards the top, that is to say, directly accessible to an operator or a robot. The holding device 20 has for function to maintain the screen 10 whatever the operations to be carried out on the screen. In particular, it comprises flanges 23 capable of withstanding mechanical tension. Therefore, the screen 10 and the holding device 20 become integral for the deconstruction of the screen after clamping 110 .
The holding device 20 comprises at least two flanges 23 A, 23 B, 23 C, 23 D, each flange preferably being taken on a respective corner of the screen. For each corner, it is sufficient to tighten the screen 10 for example from the top (front side of the screen), from below (rear side of the screen) and from both sides (lateral sides of the screen) of the corner in order to maintain it. In this case, the screen 10 is maintained stationary with at least two flanges arranged on two opposite corners (diagonally on the screen).
In operation, for a better hold of the screen, three out of the four corners of the screen can be clamped. Consequently, plastic deformation actions can be carried out on the fourth corner (unclamped) without risk of damaging the flange.
It is provided a step 140 of determining the dimensions and position of the visible faceplate 12 . This makes it possible to define the straight lines (in three dimensions in a given reference), each corresponding to the intersection between the inner edges of the casing 14 and the plane of the faceplate, such as to correctly position the knives in a later step.
To this end, a possibility is offered by the holding device 20 itself: for example, the measured spacing of the flanges holding the screen 10 provides information about the height or the outer width of the screen. Thus, making it possible to roughly locate the corners of the screen. One can further position a camera 50 over one of the corners.
Laser Profilometry
Another possibility is offered by laser profilometry 150 of the screen.
Laser profilometry concerns obtaining the (three-dimensional) topography of one portion at least of the screen. A laser projects a plane beam resulting in a line of light on an area of the screen. The laser is inclined at a given angle, for example 30° to 45°, with respect to the optical axis of a camera (possibly the same camera 50 ) which scans an area where the laser line is projected and reflected in the direction of the camera such as to image the deformations of the line due to the relief, that is to say, the geometry of the screen 10 (casing, buttons, etc.). Preferably, the optical axis of the camera or the laser plane is orthogonal to the faceplate.
The movement of the camera is integral with the laser movement, for example by both being carried by a robotic arm (not illustrated). This arm makes it possible to produce a movement of translation (scanning) of the camera-laser assembly particularly parallel to the faceplate.
The observation by the camera of the deformed laser line makes it possible, thanks to a prior calibration of the camera-laser system and the implementation of an image processing algorithm well known in the field, to know the 3D coordinates in a coordinate system (for example that of the robot) of each point of relief of the screen having been scanned by the camera-laser assembly.
Advantageously, it is not necessary to recreate a complete representation of the relief of the screen, but only to have knowledge of at least the coordinates of certain characteristic points.
The laser line can be scanned (automatically) on the four sides of the screen, such as to determine the characteristic points corresponding to the transition points between the faceplate 11 and the casing 14 of the screen, that is to say such as to define the contour (perimeter) of the visible faceplate 12 .
This step of laser profilometry 150 makes it possible to locate the surface of the faceplate in space with respect to a given reference and also to check the state of flatness and possible degradation of the surface of the faceplate 11 , and emit an alarm or remove a screen 10 from the deconstruction circuit if need be.
Weakening
For the plastic deformation 120 of the frame, significant mechanical forces are exerted thereon. However, the constraints are mainly focused on the corners of the frame. Therefore, it can be provided a step 130 comprising weakening the frame 13 , particularly the corners thereof.
The step of weakening makes it possible to reduce mechanical resistance upon plastic deformation of the frame, that is to say of the material(s) composing it or the junction between these materials in a corner of the frame. Hence, it makes it possible to decrease the mechanical forces required to plastically deform the frame 13 —hence of the opening of the screen 10 —and makes it possible to promote a possible breakage of the frame 13 on the weakened areas.
This weakening 130 can be achieved by removing material, modifying the form or physical properties of the frame. Several solutions are possible.
by mechanical action:
it may be provided a machining of the frame, particularly of the corners, using an abrasive tool (grindstone, cutter, drill). It may also be provided a partial cut of the frame, particularly the corners, with a cutting tool (circular saw, cutting tool, . . . )
by thermal action:
it may be provided cryogenic treatment of the frame 13 to make it more breakable, or
the heating of the frame 13 to reduce its mechanical strength.
It can be provided to drill the corners of the frame 13 covering the faceplate ( FIG. 2B ), without damaging the faceplate 11 . The drilling may be on all or part of the thickness of the frame 13 covering the faceplate.
It can be provided that the weakening step 130 precedes the plastic deformation step 120 .
It can be provided that the weakening step 130 and plastic deformation step 120 be simultaneous, also for example, thanks to the shape of a tool 30 described later.
The weakening step 130 makes it possible to deform, cleave, split, crack, or break the frame.
The mechanical forces to be applied (force and/or torque) for the plastic deformation of the frame, serve to release the faceplate 11 from the frame 13 which maintains it. Hence, it is possible to only weaken the frame 13 on the part covering the faceplate 11 (front side of the screen), particularly in the corners.
For the plastic deformation of the frame, the mechanical forces are applied by a plastic deformation device.
Plastic Deformation Device
The plastic deformation device comprises a knife 30 connected to a means 40 for transmitting a force, for example a jack, possibly rotatable.
By knife, also known as a wedge is meant an instrument or oblique-sided mechanical piece of essentially prismatic shape whereof two main sides, in this case a leading edge 31 , or ridge, intersect at a sharp angle. Unlike cutting tools that require sharpening, the knife 30 is a tool of force concentration. Furthermore, the implementation of the knife 30 aims to deform the frame, possibly until it breaks. It is thus not only distinguished from cutting techniques but further by degree of precision that they require.
The shape of the knife 30 ( FIGS. 4A, 4A ′, 4 B, 4 B′, 4 C, 4 C′) makes it possible to focus the constraints transmitted by the jack on the leading edge 31 , which serves to concentrate the mechanical forces. Preferably, the shape of the leading edge 31 is rectilinear and substantially perpendicular to the plane of the faceplate or has a sharp angle ranging between 45 and 90° with respect to the plane of the faceplate ( FIGS. 4A ′, 4 C′).
In one embodiment that is non-illustrated, the knife 30 comprises along its entire length a rectilinear groove extending along an axis of elongation parallel to the plane of the screen and the frame, that is to say, orthogonal to the travelling direction of the knife, such that the frame can be inserted in said groove and be in abutment with the edges thereof during the pushing movement of the knife, thereby constraining the elastic or plastic deformation of the frame.
The leading edge 31 can be configured to switch between the faceplate 11 and the frame 13 (particular FIGS. 4B, 4B ′). It makes it possible for example to be put in contact with the frame 13 during the initial positioning (see below), and remain in contact with the frame 13 when applying force. It makes it possible to exert a spacing and distorting function of the frame 13 with respect to the faceplate 11 .
The leading edge 31 may be, in combination ( FIGS. 4A ′, 4 C′) or alternatively configured to pass between two adjacent sides of the frame, that is to say to concentrate the mechanical forces in a corner thereof.
The leading edge 31 may have a weak opening angle (less than 45°) and be extended by a thicker part (whereof the opening angle is larger. This shape makes it possible to lift the frame 13 (upon applying a mechanical force parallel with the plane of the faceplate) and lock the frame 13 on the knife, enabling a better thrust during the movements thereof. The angle of incidence 31 may vary switching for example from 25° on the drive line 31 to 50° after a few millimeters. The portion in contact with the faceplate 11 is flat, such as to slide more easily on the faceplate without causing jamming or damage to the integrity of the faceplate.
The knife 30 can have several forms:
a flat effective area, practical during the spacing of the flat portions of the frame ( FIGS. 4B, 4B ′),
a flat effective area with a sharp corner ( FIGS. 4A ′, 4 C′) or in curved or rounded form (not represented) practical during the spacing of the corners of the frame,
an area with several geometries (flat and/or sharp and/or curved corner . . . ), to be taken from any location of the frame 13 (form not represented).
Depending on the form of the knife 30 , the weakening step 130 and the plastic deformation step 120 can be implemented not only simultaneously but further with a single tool, in this instance the plastic deformation device comprising the knife 30 . For example, as illustrated in FIG. 4C ′, the leading edge 31 non parallel with the plane of the faceplate makes it possible to weaken the frame by focusing forces. The two main sides, that is to say the flanks on either side of this leading edge 31 make it possible to plastically deform the frame during the relative movement between the knife 30 and the frame.
Initial Position
Before applying the mechanical forces required for the plastic deformation of the screen, the plastic deformation device is manually and/or automatically placed in initial position, by a relative movement between the latter and the screen 10 (the screen 10 being preferably maintained).
Preferably, in the initial position, the plastic deformation device is in contact with the frame 13 or the casing 14 of the screen.
Plastic Deformation
Once placed in the initial position, the plastic deformation device is brought in relative movement with respect to the screen 10 such as to exert a mechanical force (force and/or torque) on the frame 13 to deform it ( FIG. 5A to 5D ).
The relative movement may be implemented according to at least one of the following trajectories: a rectilinear trajectory parallel with the plane of the faceplate ( FIG. 6A ), a rectilinear trajectory non parallel with the plane of the faceplate ( FIG. 6B ), a curved trajectory ( FIG. 6C ) or a combination of these movements ( FIG. 6D ).
A curved trajectory allows for example to raise the portion of the frame 13 covering the front side of the faceplate 11 with a rotational movement of the knife 30 with respect to an axis of rotation parallel to the side of the screen 10 whereon the plastic deformation is implemented ( FIG. 7 ).
The plastic deformation of the frame 13 makes it possible to deform the frame hence, to release the faceplate 11 from the screen. The deformation is relative and even proportional with the force applied by the knife 30 connected to a force transmission means 40 . It can be provided that the plastic deformation will cause to the mechanical rupture of the frame.
The plastic deformation is not a cutout from the frame. Advantageously, the knife 30 , even from metal does not need to be particularly sharp. And compared to the cutout solutions requiring precision and special mastery, the present solution is easier to implement and less costly since the knife 30 is not a consumable item as is a saw blade for example.
It is worth noting that during deformation, one or several knives (identical or not) can be used on a same screen simultaneously or sequentially. The relative movements of each knife 30 may be independent: each knife 30 can have a similar or different movement to/from one another.
Typically, after the measurements of the dimensions of the position of the screen 10 by laser profilometry 150 , a computer algorithm determines the trajectories (movement) of each knife 30 (direction, way, angle of rotation, starting point and the point of arrival of the movement of the knife by means of the jack 40 ).
In accordance with the determined trajectories, a robot then manipulates the knife or knives, which has for effect to open the frame 13 of the screen 10 by plastic deformation of the frame.
For example, the knife 30 carries out a translation of a few centimeters in the plane of the faceplate, then a rotation of 90° around the axis parallel to the edge of the screen 10 whereon the knife 30 is performing the deformation, such as to raise the edge, which is hence no longer above the faceplate.
The same operation can be carried out over the entire length of the frame, so that a whole side of the frame 13 be entirely open. The same operation can be performed on each side of the frame.
The flange system of the holding device 20 can be applied at any point that is not on the trajectory of the knife.
Check
It can be provided at least a camera (for example the camera 50 ) to view and/or control on the console of an operator the proceedings of the application of the plastic deformation forces. The operator may then validate the step of plastic deformation or invalidate it, for example via a push button.
In case of validation that is to say when the frame 13 has been sufficiently open to be able to remove the faceplate, the faceplate 11 may then be removed 160 from the frame.
In case of invalidation, a new sequence of deformation can be applied, for example by modifying the parameters representative of force, or the stroke length of the knife.
Holding Device
The holding device 20 comprises at least one flange 23 .
The flange 23 is taken on one side of the screen, preferably by remaining as far as possible from the visible faceplate 11 ( FIG. 8 ). It can also be taken behind and/or in front, as long as it does not hinder the execution of the method.
The flange 23 can be fixed on a stationary support (for example a table) and/or a mobile system able to move (for example a robot).
In the case where the flange 23 and hence the screen 10 held therein, is mounted on a mobile system, the position of the flange in space is always known. Thereby, the position of the screen 10 in space is also known.
For the flange, it can be provided a mechanical clamping system, a suction system, a magnetic system, a system based on adhesive material, or a combination of these possibilities.
In one embodiment ( FIG. 11 ), the holding device 20 comprises a set of plates 24 (drilled at each end) and screws, each set of plates and screws acting as flanges.
The screen 10 is maintained by two or three plates 24 each screwed to a corner of the screen 10 on a special table, of machining table type (that is to say, with special mobile notches to place and tighten the screws so that they be stationary through tightening) at multiple points ( FIG. 11 ).
The dimensions of the plates are preferably selected such that they press on the screen 10 without covering the visible faceplate 12 and preferably without also covering the faceplate 11 concealed under the casing.
Preferably, the screws crossing each plate are in contact with the screen.
In an embodiment ( FIG. 3 ), the screen 10 is maintained by a (possibly automatic) clamping system.
An embodiment of the clamping system is illustrated in FIG. 9 , maintaining a screen 10 in the latter being illustrated in FIG. 3 .
The clamping system comprises:
a support 21 able to be mounted on a mobile tool (for example a robot), a set of branches 22 A, 22 B, 22 C, 22 D independent from each other and mounted on the support 21 , typically three or four branches. Preferably, each branch is mounted in rotation with respect to the support, according to an axis of rotation perpendicular to the plane of the support. Preferably, each branch is telescopic in order to be able to modify its length ( FIG. 10 ), a flange 23 A, 23 B, 23 C, 23 D positioned at the end of each branch. Preferably, in order to be able to orient it, each flange is mounted in rotation with respect to the branch which supports it, according to an axis of rotation perpendicular to the plane of the support. Each flange comprises two plates 24 mobile with respect to each other thanks to two screws. The tightening of the flange is carried out for example thanks to a relative rectilinear movement of the two plates with respect to one another.
It can be provided that each flange 23 (set plate+screw) is adjustable in height with respect to the respective branch 22 which supports it, for example by means of a helical connection between the flange 23 and the branch 22 of a sliding pivot joint lockable in translation by means of a stop pin in translation of the flange 23 with respect to the branch 22 which supports it. This last feature allows for the clamping device to be able to receive and clamp any type of screen, regardless of its length, width, or depth.
In order to maintain a 10 screen with such a holding device, it is provided on a given arm:
First, the arm is moved away, for example by extending it to a maximum, The screen 10 is positioned on the support, faceplate 11 upwards, The arm undergoes a rotation in order to be parallel to a diagonal of the screen, The arm is retracted, such that the screws of the flanges are pressed on a corner, thanks to a rotation of the flange, The clamp is tightened, thereby blocking the screen 10 by the corner. Such a holding device 20 can be adapted to all screen sizes.
Once the screen 10 is clamped, the step of laser profilometry 150 can be for example implemented.
Withdrawal of the Faceplate
Once the plastic deformation carried out, the faceplate 11 is no longer maintained by the frame. The flange may be removed.
The withdrawal operation 160 may be performed by an operator and/or an automated mobile system (robot).
The only remaining links between the faceplate 11 and the rest of the screen 10 are usually flexible electronic cards and/or cables. These various links can be cut or broken, including during the removal of the faceplate, thanks to a fairly rapid movement and/or with enough force.
During this action, little or no force is applied on the members placed behind the faceplate 11 : filters and diffusers, possible backlight lamps, electronic cards, etc. Thus, making it possible to maintain their integrity.
The faceplate 11 can be removed from the frame 13 in several ways:
the faceplate 11 is drawn along a trajectory comprising an initial movement in a direction substantially perpendicular to the plane of the frame 13 (before deformation), for example by suction cups, the faceplate 11 can be removed by sliding it along the screen 10 , like a sheet of paper being removed from an envelope, the faceplate 11 can be lifted by a lever, thanks to a lever tool such as a screwdriver, spatula, etc. Once lifted, the faceplate 11 can be manipulated manually or by an automated system with a gripping tool that is non-aggressive for the faceplate 11 : suction cup, pliers, venturi effect, . . . the screen can be turned around to remove the faceplate 11 by gravity.
For example, an operator places a flat tool (of screwdriver type) between the faceplate 11 and the deformed frame 13 . The operator brings the flat part of the tool under the faceplate 11 and by leverage effect, lifts the faceplate. Thus, he can without moving the screwdriver in his hand, grab the faceplate 11 with the other hand and remove it. The frame 13 having been deformed such that the opening created by the deformation be greater than the faceplate, this operation is simple to implement and does not pose any particular risk for the faceplate, the operator or the other members of the screen.
The faceplate 11 having been withdrawn, the operator can, in the same manner, remove the filters and diffusers under the faceplate.
Once the faceplate 11 removed, the rest of the screen 10 may undergo another deconstruction treatment. In particular, the screen 10 may undergo a method of removing the backlight lamps. | The invention relates to a method for at least partially deconstructing a flat display screen ( 10 ), the screen ( 10 ) comprising: —a substantially flat faceplate ( 11 ) comprising four side edges and a visible part ( 12 ) on a front face of the screen ( 10 ), said visible part ( 12 ) being intended to display images, —a frame ( 13 ) that mounts the faceplate ( 11 ) by partially covering at least the front face and two side edges, the method comprising steps of: —disposing ( 100 ) a single screen ( 10 ) on a holding device ( 20 ), and —clamping ( 110 ) the single screen ( 10 ) to the holding device ( 20 ). The method is essentially characterized in that it also comprises a step of: —effecting plastic deformation ( 120 ) of the frame ( 13 ) while maintaining the integrity of the faceplate ( 11 ). | 7 |
This is a continuation of application Ser. No. 150,002 filed May 15, 1980, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to apparatus for removing foreign matters in liquid, and more particularly to apparatus for removing foreign matters such as marine organisms from cooling seawater used in a condenser etc. of a cooling seawater system.
Seawater is sometimes employed as cooling water for condensers in thermal and nuclear power stations etc., and the inflow of marine organisms etc. into the cooling seawater has heretofore been prevented by means of a screen disposed at a seawater intake, and so on. However, marine organisms etc. which breed in a waterway behind the screen or a piping system are introduced into the water chamber of the condenser by a water current and block the inlet part of a cooling pipe, or they accumulate in the pipe to such an extent so as to reduce the quantity of the cooling water. Moreover, the marine or organisms or the like may even cause leakage due to the erosion and the corrosion pitting of the pipe material. It is also a cause for the frequent occurrence of the above troubles that, although chlorine had been injected into the seawater for suppressing adhesion or growth of organisms such as shells, the chlorine injection process has been stopped for the reason of such adverse influence as destroying beneficial marine organisms.
There has been known a technique wherein, in order to prevent such drawbacks, a filter is disposed in the cooling water inlet pipe of the condenser to remove foreign matters such as marine organisms from the system before the cooling water flows into the water chamber. This kind of apparatus is shown in U.S. Pat. Nos. 3,875,063, and 3,828,930 wherein a cylindrical housing and a cylindrical filter disposed coaxially therein define an annular space therebetween, and the housing is provided with a radial inlet pipe at the upper portion of the filter, and an outlet pipe arranged axially of the filter at the lower portion. By deflector means provided in the radial inlet pipe swirling fluid flow is formed around the filter. It seems that since the swirling fluid flow decreases in its velocity toward the outlet pipe and the fluid in the annular space flows into the filter, there are fluid flows carrying solids to be separated near the outlet pipe so that the filter may be clogged near the outlet pipe and a practical filtering face is reduced. In both of these apparatus it is required that, during foreign matter extracting operations, the quantity of extracted water is small; a rise in the pressure loss due to the installation of the apparatus is low; and a clogging of a strainer does not occur.
More particularly, when the foreign matters are extracted, the cooling seawater is simultaneously extracted. Therefore, decreasing the quantity of the cooling water to the minimum is necessary for maintaining the performance of a condenser. In addition, the pressure loss corresponding to a water current resistance is incurred by the installation of such apparatus in the piping system. The increase thereof results in an increase in the pumping power of the cooling water, and therefore needs to be suppressed. Further, the clogging of the filter surface due to the foreign matters needs to be avoided because such clogging results in an abnormal rise in the pressure loss.
Apparatus for removing foreign matters meeting the above requirements are desired.
SUMMARY OF THE INVENTION
An object of the invention is to provide foreign matter removing apparatus which effectively removes foreign matters without clogging a filter.
Another object of the invention is to provide foreign matter removing apparatus which grasps and removes foreign matters such as marine organisms existant in cooling seawater, within water current, without rising pressure loss of the water current.
A further object of the invention is to provide foreign matter removing apparatus which removes foreign matters in liquid current while preventing a filter from being clogged, with a relatively small amount of liquid being extracted.
Briefly stated, the invention resides in providing an apparatus wherein a liquid carrying foreign matters directed to a filter surface and is swirled around the filter, with the foreign matters being moved in the direction opposite to that of an outlet liquid current of the filter thereby preventing clogging of the filter and a rise in the pressure loss.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front partial cross sectional view of an embodiment of foreign matter removing apparatus according to the invention;
FIG. 2 is a cross sectional view taken along a line II--II of FIG. 1;
FIG. 3 is a cross sectional view of a modification of a filter used in the apparatus of FIGS. 1 and 2; and
FIG. 4 is a front partial cross sectional view of another embodiment of foreign matter removing apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and, more particularly, to FIGS. 1 and 2, according to these figures, a foreign matter apparatus used, for example, for removing foreign matter such as marine organisms from cooling sea water used in a condenser, etc. of a cooling sea water system includes a cylindrical casing generally designated by the reference numeral 1 with an upper end plate 3 and a lower end plate 5 for forming a closed housing. The casing 1 has a straight cylindrical upper portion 7 and a conically extending lower portion 9. An inlet pipe 11 is joined to the casing 1 on the straight cylindrical upper portion 7 for introducing seawater into the casing 1 with the inlet pipe 11 extending radially outwardly from the casing 1. An outlet pipe 13 is mounted on the upper end plate 3, with a center axis of the outlet pipe 13 being coaxial with a center axis of the casing 1 and one end 14 of the outlet pipe 13 projecting into the casing 1. A filter 15, formed in a conical shape with an inclination angle θ 1 is mounted on the end 14 of the outlet pipe 13. The filter 15 has a plurality of fine holes 17 on the conical face and a lower end facing the lower end plate 5 with a small gap therebetween. The holes 17 are smaller than a diameter of a cooling pipe of a condenser (not shown), but they may be mesh smaller than the diameter of the cooling pipe. An extraction pipe 19 is mounted on the conically extending lower portion 9 of the casing 1 near the end portion 16 of the filter 15. A plate deflector 21 is provided in a liquid flow from the inlet pipe 11 and is rigidly connected to a shaft 20 so as to be operated by a driving device 23 disposed outside of the casing 1.
The angle θ I of the conical face of the filter 15 is at least 5°, and the conically extending lower portion 9 of the casing 1 is inclined at an angle θ 2 of about the same angle as that of the filter 15, so that an annular liquid passage formed between the casing 1 and the filter 15 joined to the inlet pipe 13. The annular liquid passage is reduced in its sectional area in a plane perpendicular to the axis of the casing from the upper end 24 of the casing toward the lower end portion 16.
In the above construction, inside the casing 1, a cylindrical passage having no filter surface is formed on the liquid inflow side in the upper portion, while a conical and annular passage is formed between the casing 1 and the filter 15 in the lower portion.
The foreign matter removing apparatus according to this invention operates in the following manner:
With the deflector 21 located in a state parallel to the center axis of the inlet pipe 11 without being turned, the liquid flowing in from the inlet pipe 11 bends and flows downwards along the outer surfaces of the outlet pipe 13 and the filter 15, and the liquid current having passed through the holes 17 moves upwards oppositely and reaches the outlet pipe 13. The foreign matters such as marine organisms are seized by the filter 15. Accordingly, when the apparatus is allowed to stand as it is, the filter 15 is naturally clogged with the foreign matters to bring about a rise in the differential pressure upstream and downstream of it.
Subsequently, as shown in FIG. 2, the deflector 21 is turned in either direction and is set at a certain angle to the center axis of the inlet pipe 11 so that the inflowing liquid changes its flow direction along the deflector 21, and it swirls and flows along the outer wall of the outlet pipe 13 disposed within the apparatus. An effective swirling stream is produced by actuating the deflector 21 and subjecting the liquid to an approach run by means of the annular liquid passage formed by the casing 1 and the outlet pipe 13. The liquid flowing down while swirling round the filter 15 flows into the filter 15 through the holes 17, and it changes its flow direction and flows out into the outlet pipe 13. The foreign matters enter from the inlet pipe 11 along with the liquid current, descend in the conical annular passage along with the swirling stream, gather in the lower part of the casing 1 as shown by foreign matter 25 in FIG. 1, and revolve together with the liquid current. Accordingly, the foreign matter 25 can be quickly discharged from the extracting pipe 19 by opening the extracting pipe 19. More specifically, by properly selecting θ 1 and θ 2 of the filter 15 and the casing 1, for example at least 5°, the foreign matter 25 can be caused to stay in a concentrated condition in the lower portion of the casing 1. In other words, a part in which no foreign matter 25 exists in a surface of the filter 15 outside the concentrating part (in FIG. 1, the side of the filter 15 connected to the outlet pipe 13) can be formed. This is based on the function that the foreign matter 25 moves towards the concentrating part or the filter end portion 16 along the filter surface having the angle θ 1 together with the swirling stream. This fact simultaneously signifies that the liquid current at the filter surface is averaged, with the result that a rise in the flowing pressure loss at the passage through the holes 17 is suppressed. In addition, the function in which the foreign matter 25 moves along the filter surface in the manner described above results in causing the foreign matter 25 to flow towards the extracting pipe 19 more effectively when the extracting pipe 19 has been opened. Therefore, the foreign matter 25 comes away from the filter surface, which is effective to prevent the clogging. Moreover, even when the quantity of extraction is small, the foreign matter 25 can be fully removed. Further, this phenomenon permits, by operation of the deflector 21, a scraping off the foreign matter seized on the filter surface under an irregular state in the foregoing case where the deflector 21 has not been operated, and periodical turning of the deflector 21 as shown by an arrow 22 of FIG. 2 to give rise to the swirling streams both counterclockwise and clockwise. Besides, even when the deflector 21 is operated, the inlet liquid flow can be always kept in the open state, so that safety is ensured without any abnormal pressure rise.
The apparatus according to the invention can be operated such that after the foreign matter 25 is seized without operating the deflector 21, the extraction pipe 19 is opened in response to the differential pressure upstream and downstream of the filter 15. The foreign matter 25 may be removed by operating the deflector 21 to swirl the liquid, such that the deflector 21 is operated in advance, and when a differential pressure to a certain extent has arisen, the extracting pipe 19 is opened to remove the foreign matter 25, or such that the deflector 21 and the extracting pipe 19 are simultaneously operated.
In this apparatus, the inlet pipe 11 is provided near the outlet portion 24 of the filter 15, and most of the filtering face (in which the holes 17 are made) is disposed in the direction opposite to the outlet pipe 13, so that the foreign matters carried by the liquid or water has a flow direction toward the filter end portion 16. About the filter end portion 16, the liquid flow is slower than the outlet portion 24. Therefore, it is difficult for the the foreign matter removed from the surface of the filter 15 to again be deposited on the filter 15. Further, since the filter 15 and the casing 1 have inclination angles θ 1 , θ 2 of at least 5°, the centrifugal force can be maintained until the filter end portion 16 without significant losses so that the foreign matter 25 can be concentrated around the filter end portion 16.
FIG. 3 shows a modification of the filter 15 in FIG. 1, wherein a filter 15a comprises a conical portion 18a which is similar to the filter 15, and a cylndrical portion 26. The outlet 24 of the filter 15a faces an upper end plate 3 of a casing 1 which is the same as in FIG. 1 with outlet pipe 13a being provided on the upper end plate 3 facing the upper end portion 24a of the filter 15a so that liquid from the filter 15a can be discharged through the outlet pipe 13a.
In the modification of FIG. 3, swirling and downward movement of the liquid and foreign matter are compared to the apparatus of FIG. 1 reduced, however, the filtering face is enlarged, so that it can be put into practice.
FIG. 4 shows foreign matter removing apparatus of another embodiment according to this invention, which differs from the embodiment of FIG. 1 in that a larger space is provided between the filter 15 and the bottom of the casing 1. In addition, a lid 31 is disposed at the tip of the filter 15. The lid 31 may well be one provided with apertures. The space permits the concentrating part to shift still below the tip of the casing 1. That is, it permits the foreign matter to come away from the filter 15 and prevent the clogging more effectively. Although, in FIG. 4, the extraction pipe 33 is provided on the lower end plate 5a at the bottom of the casing 1, the effect does not differ at all even when it is located on the side of the casing 1 as shown in FIG. 1.
It is added that the foreign matter apparatus according to this invention is not restricted to the vertical installation as shown in FIGS. 1, 3, and 4 but that even in case of the inverted installation or the lateral installation, the operation and effects above described do not basically vary though the extents somewhat differ depending upon the weights of foreign matter, etc.
According to the embodiments of this invention described above, the following effects may be achieved:
(1) Foreign matter such as marine organisms seized on the filter surface can be effectively removed from within the cooling seawater by the operation of a deflector 21, and the part for concentrating the foreign matters is formed along the filter surface, whereby the removal apparatus free from clogging is provided.
(2) The deflector 21 disposed in a manner to be contained in the apparatus, is manipulated without blocking the waterflow during the operation, and can make the flow at the filter screen uniform and confine the rise of the pressure loss to the minimum.
(3) The conical annular liquid passage is formed by the combined shape of the conical surfaces of θ 1 and θ 2 , whereby the clogging of the filter 15, 15a can be perfectly prevented by the swirling stream due to the operation of the deflector 21 and the stream shifting through the liquid passage, and simultaneously, the quantity of extraction during the removing of the foreign matter removing can be made small (at most 10% of the quantity of inlet cooling water was sufficient). p (4) The approach-run liquid passage defined by the casing 1 and the outlet pipe 13 only in FIGS. 1 and 2 promotes the swirling stream, and moreover, since no filter surface confronts the water current flowing in from the inlet pipe 11 at a high flow velocity, foreign matter does not stick into the filter surface.
Accordingly, by installing such apparatus according to this invention on the inlet cooling water system of a heat exchanger such as condenser, foreign matter such as marine organisms can be effectively removed before flowing into the heat exchanger or the like, and a predetermined performance can be maintained.
As a beneficial result according to this invention, it becomes possible to obtain foreign matter removing apparatus which is used for heat exchangers etc. and by which foreign matter such as marine organisms in seawater can be seized and removed within the water current. | Apparatus for removing foreign matter in liquid which includes a cylindrical housing, a radial inlet pipe provided on an upper portion of the housing, an outlet pipe axially mounted on the housing at the upper portion, a conical cylindrical filter disposed in the housing and connected to the end of the outlet pipe so as to discharge the liquid from the inlet pipe through said filter and the outlet pipe, a deflector for deflecting the liquid from the inlet pipe so as to swirl it round the filter, and an extracting pipe provided on the housing at the bottom portion. The filter extends conically from the inlet pipe or outlet pipe toward the bottom of the casing. The liquid from the inlet pipe is swirled by the operation of the deflector and directed downward by the position of the filter while swirling. The foreign matter in the liquid and deposited on the filter are swirled by the swirling liquid, condensed by centrifugal force and downward movement. The condensed foreign matters are extracted by an opening up of the extracting pipe. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to cutting devices or systems and, more particularly, to a cutting device or system operable for repeatedly cutting drill pipe, tubing, coiled tubing, and/or wireline so as to be especially suitable for use in a lightweight intervention package and/or in substitutions for replacing at least one BOP in an intervention package.
[0003] 2. Background of the Invention
[0004] Blowout Preventer (B.O.P.) stacks are frequently utilized in oilfield wellbore Christmas trees and subsea intervention operations such as, for instance, lower riser packages in offshore wells. B.O.P. stacks may include a first set of rams for sealing off the wellbore and a second set of rams for cutting pipe such as tubing, wireline and/or intervention tools. However, B.O.P. stacks are quite bulky and heavy, which are undesirable features especially in lower riser packages for undersea operation where space is often at a premium. B.O.P. stacks tend to be expensive for installation and removal due to the need for heavy lifting equipment. Moreover, if maintenance is required, then the high maintenance costs for utilizing B.O.P. stacks for intervention purposes severely limits the wells that can be economically reworked. B.O.P. stacks may frequently require maintenance after cutting pipe For instance, the cut pipe may become stuck within the B.O.P. stack blocking other operations.
[0005] Consequently, those skilled in the art will appreciate the present invention that addresses the above problems.
[0006] The following patents discuss background art related to the above discussed subject matter:
[0007] U.S. Pat. No. 6,601,650, issued Aug. 5, 2003, to A. Sundararajan, which is incorporated herein by reference, discloses apparatus and methods for replacing a BOP with a gate valve to thereby save space, initial costs, and maintenance costs that is especially beneficial for use in offshore subsea riser packages. The method provides a gate valve capable of reliably cutting tubing utilizing a cutting edge with an inclined surface that wedges the cut portion of the tubing out of the gave valve body. A method and apparatus is provided for determining the actuator force needed to cut the particular size tubing.
[0008] U.S. Pat. No. 8,353,338, issued Jan. 15, 2013, to J. Edwards, discloses a well bore control valve comprising a housing defining a throughbore, the throughbore adapted to receive a first tubular. The valve further comprises first and second gates located within the housing, the gates being movable in different directions transverse to the throughbore between the throughbore open position and the throughbore closed position. Movement of the gates from the throughbore open position to the throughbore closed position, in use, shares a tubular located between the gates. The valve also comprises a first seal seat performing a seal of one of the gates in the throughbore closed position to seal the throughbore.
[0009] U.S Patent Application No. 20100218955 discloses an oil field system comprising a main body having a bore therethrough, the main body having a connection at one end of the bore for, in use, connecting the main body to an existing wellhead, tree or other oil field equipment, a transverse cavity through the bore, the cavity having at least one opening to the outside of the main body, a plurality of flow control systems for insertion, at different times, into the cavity in order to selectively control fluid flow through the bore, wherein the plurality of flow control systems includes a gate valve and drilling BOP rams.
[0010] The above prior art does not disclose the cutting system operable for cutting drill pipe while still being very lightweight as described in the present specification. Consequently, those skilled in the art will appreciate the present invention that addresses the above and/or other problems.
SUMMARY OF THE INVENTION
[0011] An object of the present invention is to provide an improved cutting apparatus and/or system.
[0012] Another possible object of the present invention is to provide a non-sealing compact cutting device to cut drill pipe at least up to 3½ inches and allows use with a gate valve for sealing the wellbore with the combination to substitute for a much heavier BOP.
[0013] Yet another possible object of the present invention is to provide a compact cutting system with a short stroke length and/or piston rod assemblies and/or lesser fluid volumes at different vertical heights.
[0014] Accordingly, a compact cutting system is provided that is operable for cutting 4½ inch 16.60 lb/ft drill pipe, coiled tubing, wireline and sinker bar. The cutting system comprises a housing defining a throughbore, a first gate and a second gate mounted within the housing. The first gate and the second gate are moveable transversely with respect to the throughbore between an open position and a closed position. In one embodiment, the first and second gates comprise openings therein that prevent sealing of the throughbore in the closed position.
[0015] The compact cutting system may further comprise a gate valve wherein the compact cutting system is operable for substitution of at least one BOP.
[0016] In one possible embodiment, the system may comprise a first piston and a first piston rod operably connected to the first gate with a first stroke length. A second piston and a second piston rod is operably connected to the second gate with a second stroke length. The first and second stroke lengths are less than a diameter of the throughbore.
[0017] In one possible embodiment, the first gate and the second gate each comprise a gate bore therethrough, in the open position each gate bore is in surrounding relationship to or form a portion the throughbore. In one embodiment, the gate bore is elliptical.
[0018] In one possible embodiment, when the throughbore is oriented vertically then the first piston and first piston rod is mounted to the housing at a higher vertical position than the second piston and second piston rod.
[0019] In one embodiment, the first piston and the second piston each comprise a piston surface with a diameter between one and one-half and two and one-half times as large as a diameter of the throughbore.
[0020] The compact cutting system may further comprise a first piston chamber for the first piston and a second piston chamber for the second piston. The first piston and the second piston are mounted so that all of each piston surface is available for engagement with hydraulic fluid for use in closing the gates. The piston rod end of the piston may then be utilized for opening the gates.
[0021] In one possible embodiment, the cutting system may comprise a first seat mounted in the throughbore adjacent the first gate. The first seat has a first seat interior. The first seat interior decreases in diameter with distance away from the first gate. A second seat is mounted in the throughbore adjacent the second gate. In a similar manner, the second seat interior decreases in diameter with distance away from the second gate. In one embodiment, the interior of the seats may be elliptical.
[0022] In one possible embodiment, the compact cutting system may comprise a first seat mounted in the throughbore adjacent the first gate, a second seat mounted in the through bore adjacent the second gate. The first gate and the second gate may comprise a passageway therethrough to prevent sealing between the first gate and the first seat and between the second gate and the second seat.
[0023] In one possible embodiment, the first piston rod and the second piston rod comprise a length less than two and one-quarter times as large as a diameter of the throughbore. The first piston and the second piston each comprise a piston surface with a diameter between one and one-half and two and one-half times as large as a diameter of the throughbore.
[0024] These and other objects, features, and advantages of the present invention will become clear from the figures and description given hereinafter. It is understood that the objects listed above are not all inclusive and are only intended to aid in more quickly understanding the present invention, not to limit the bounds of the present invention in any way.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The above general description and the following detailed description are merely illustrative of the generic invention, and additional modes, advantages, and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention. A more complete understanding of the invention and many of the attendant advantages thereto will be readily appreciated by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts and wherein:
[0026] FIG. 1 is a front elevational view, in section, of a compact cutting system in the open position in accord with one possible embodiment of the present invention.
[0027] FIG. 2 is a front elevational view, in section, of a compact cutting system in the closed position in accord with one possible embodiment of the present invention.
[0028] FIG. 3 is a side elevational view, in section, of a compact cutting system in accord with one possible embodiment of the present invention.
[0029] FIG. 4 is a top elevational view of a compact cutting system in accord with one possible embodiment of the present invention.
[0030] FIG. 5 is a front elevational view of a compact cutting system in accord with one possible embodiment of the present invention.
[0031] FIG. 6 is an exploded view of a compact cutting system in accord with one possible embodiment of the present invention.
[0032] FIG. 7A is an enlarged view of a gate in accord with one possible embodiment of the present invention.
[0033] FIG. 7B is an enlarged view of a gate oriented in a reversed position with respect to FIG. 7A in accord with one possible embodiment of the present invention.
[0034] FIG. 8 is a schematic view of a compact cutter and gate valve that may be utilized in a subsea installation is place of at least one BOP (blowout preventer) in accord with one possible embodiment of the present invention.
[0035] FIG. 9 is an elevational view of a cutter in accord with one possible embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0036] 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. 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.
[0037] Abbreviations include the following:
[0038] API—American Petroleum Institute
[0039] DNV—Det Norske Veritas (The Norwegian Veritas)
[0040] ISO—International Standardization Organization
[0041] ROV—remotely operated vehicle
[0042] NACE—National Association of Corrosion Engineers
[0043] QTC—Qualification Test Coupon
[0044] The use of CCD 10 complies with codes and standards including:
[0045] API 6A, Specification for wellhead and Christmas tree equipment, 20th Edition, October 2010;
[0046] API 16A, Specification for Drill-through equipment, 3rd Edition, June 2004;
[0047] API 16D Control Systems for Drilling Well control Equipment, 2nd Edition, July 2004;
[0048] NORSOK D-002, Well intervention equipment, Revision 2, June 2013;
[0049] DNV-OS-E101, Drilling Plant, October 2013;
[0050] ISO 13533, Drilling and production equipment—Drill-through equipment, 1st Edition, December 2001;
[0051] API 17G, Recommended practice for completion/workover risers, 2 nd Edition, July 2006
[0052] NACE MR0175/ISO 15156, Petroleum and natural gas industries—materials for use in H2S-containing environments in oil and gas production, 2nd Edition, October 2009.
[0053] Referring now to the drawings and more particularly to FIG. 1 , there is shown one possible embodiment of a compact cutting device or system which may be referred to herein as CCD 10 . Housing 12 defines throughbore 14 with axis 16 . Flange connection 18 at the bottom end, which may comprise studs or the like, may be utilized for connection with well equipment such as subsea installations, well intervention equipment, and the like. Another flange connection at the top end may connect to other well equipment such as a gate valve or the like. One embodiment of CCD 10 comprises a 7⅜ inch throughbore, with a 10K psi pressure rating. The top and bottom connectors may comprise a 13⅝ inch 10K psi studded connectors and/or flange connections. In one embodiment, CCD 10 is operable to cut pipe 68 (see FIG. 9 ) which may comprise 3½ in 13.3 lb/ft Grade E 75 drill pipe (Table 18, API 16A/ISO 13533) without leaving any snag or slug after cutting. In one embodiment, CCD 10 operates very quickly and can cut the drill string in less than 2 seconds when using an accumulator. The tests to be conducted for CCD 10 for use in an intervention package include NORSOK D-002 (API 16A/ISO 13533 Annex C) in one possible embodiment for cutting only, without the need for sealing tests as explained hereinafter. Further in one embodiment, CCD 10 weighs less than 12,000 pounds. Combined with a gate valve, the combination is much less than the weight of a BOP, which provides an opportunity for a highly desirable substitution in an intervention package. The light weight makes possible reworking of wells much less expensively than using a BOP.
[0054] Cylinder housings 20 and 22 are utilized to house pistons 24 and 26 , respectively, which drive piston rods 28 and 30 to move gates 44 and 46 between an open position and a closed position. FIG. 1 , FIG. 3 , and FIG. 9 show gates in an open or open throughbore position. FIG. 2 shows the gates in a closed position. As discussed below, in one possible embodiment moving the gates to the closed position does not necessarily provide a seal but instead in one presently preferred embodiment fluid flow may occur past the gates. However, if desired, the gates could also be made to provide a seal when closed.
[0055] In one embodiment, stroke length 32 and 34 of the pistons is relatively short so as to be less than the diameter of throughbore 14 . In one embodiment of a 7⅜ inch throughbore, the stroke length may be in the range of 5 inches. However, larger and smaller stroke lengths could be utilized. In one embodiment, compact cutting system CCD 10 advantageously utilizes considerably less volume of hydraulic fluid to operate in comparison to other units with cutting capability, e.g. a BOP. In one embodiment, the present invention utilizes less than 12 litters of hydraulic fluid for opening or closing the gates.
[0056] It will be noted that when CCD 10 is vertically oriented that piston 24 , rod 28 , gate 44 , and the axis of movement 36 of rod 28 is vertically higher than piston 26 , rod 30 , gate 46 and axis 38 of rod 30 . Likewise, piston housing 20 with associated bolts is vertically higher than piston housing 22 as shown in FIG. 1 , FIG. 2 , FIG. 5 , and FIG. 9 . The applied force is therefore directed along axis 36 and 38 of the pistons, piston rods and gates, which reduces bending forces acting on the piston rods 28 and 30 due to cutting forces applied by the gates, which are at different vertical heights.
[0057] In FIG. 2 , valve cavity 98 can be irregularly shaped due to the different vertical heights of the components. In one embodiment, the diameter of the opening into housing 12 for the components used with each cylinder is almost the same diameter of the pistons and may be used for inserting the seats, gates, and other components.
[0058] FIG. 4 shows the top elevational view whereby it can be seen that from an external view, cylinders 20 and 22 are aligned in top view, which may be considered the x-y plane. Accordingly, their associated pistons, piston rods, gates, piston axes are also aligned from this view. This is in contrast to FIG. 5 , which shows that cylinder 20 is vertically higher than cylinder 22 , which might be considered along a z-axis.
[0059] Referring again to FIG. 1 , upper seat 40 and lower seat 42 are mounted in throughbore 14 in respective recesses in housing 12 . Seats 40 and 42 may or may not seal with gates 44 and 46 when in the closed or closed throughbore position. In one embodiment, referring to FIG. 2 that shows CCD 10 in the closed position, openings are formed in gates 44 and 46 that positively prevent sealing when in the closed position as indicated by flowpath 56 through the gates 44 and 46 , which allows for fluid flow even in the closed or closed throughbore position. For example, slots may be milled into gates 44 and 46 as shown in FIG. 7A and FIG. 7B at 65 and 67 . In another embodiment additional openings, passageways, or the like may be formed with in the gates.
[0060] In another embodiment, if desired, and which is not necessarily a preferred embodiment, one or both gates could be made to seal with seats 40 and 42 , with a metal to metal seal.
[0061] FIG. 2 also shows hydraulic fluid volumes 52 and 54 that are filled with pressurized hydraulic fluid to move the gates to the closed position. It will be appreciated that the entirety of piston surfaces 58 and 60 can be utilized to create force to drive the cutters in the gates to cut drill pipe or the like within throughbore 14 . In one embodiment, diameter 62 of piston surfaces 58 and 60 may be in the range of 1½ to 2½ times the diameter of throughbore 14 . In another embodiment the diameter may be between 1½ to 2 times the diameter of throughbore 14 . In this way, a significant cutting force relative to pipe within throughbore 14 is produced, which allows the high speed powerful cutting. Use of surfaces 58 and 60 to create the force to drive the cutters takes advantage of the full surface of the pistons rather than using the side of the piston to which the piston rod is attached. Use of the piston rod side to drive the cutters would reduce the area on which the pressurized hydraulic fluid operates. Significant gate opening force is also available to open the gates by applying hydraulic fluid to the interior side of pistons 24 and 26 . The piston rods connected to the interior size limit the force to some extent and in this embodiment may result in interior piston surfaces in the range of 132 square inches. Accordingly somewhat less hydraulic fluid is required for opening.
[0062] In one embodiment, the use of a shorter piston rod also helps produce a compact size for CCD 10 . In one embodiment, piston rods 28 and 30 comprise a length less than 2¼ times the throughbore diameter and in another embodiment less than 2 times the throughbore diameter when measured from the inner surface of the piston to the end thereof.
[0063] As noted above, the cutting action is performed by moving the gates towards the wellbore so the full hydraulic piston surface area is used (not the rod end). This allows maximization of the performance and utilization of the hydraulic pressure available.
[0064] Using two gates 44 , 46 causes the tool string to be centralized during the cut action rather than it being pushed to one side. The tool string is captured inside the two gate bores 64 , 66 to provide crushing action to yield and cut the string in an area away from the upper and lower seats 40 , 42 . Gate bores 64 , 66 , comprise a minimum diameter of the throughbore, which in one embodiment is 7⅜ inches.
[0065] In one embodiment, the gate bores 64 , 66 may be oval so that the minimum of 7⅜ is along one axis of the oval with the other axis of the oval being greater than the borehole diameter. Likewise, upper and lower seat 40 , 42 may comprise an oval interior to match that of the gates.
[0066] FIG. 6 shows an exploded view of CCD 10 , including piston seals 82 , 84 , piston rod seals 86 , 88 and cylinder housing bases 90 , 92 . Other components have already been discussed but are shown here in a perspective view. It will be noted that external shapes of upper seat 40 and lower seat 42 as well as that of other components is shown.
[0067] FIG. 7A and FIG. 7B show enlarged views of gates 44 and 46 as well as cutter inserts 94 and 96 . Gates 44 and 46 may or may not utilize cutter inserts such as cutter inserts 94 and 96 . Utilizing cutter inserts 94 , 96 allows the cutting surfaces to be changed out. Cutting face or surface 76 is shown in FIG. 7A . As discussed hereinbefore, gate openings or bores 64 and 66 preferably encircle throughbore 14 and drill pipe or the like within the throughbore when in the open position. In one embodiment openings or bores 64 and 66 , with the corresponding cutter inserts 94 , 96 are preferably circular or as shown in this embodiment, are oval. Openings 65 , 67 and/or other openings can be milled into the gates and utilized to provide that the gates do not seal with the seats and allow fluid flow through the throughbore in the closed position as discussed hereinbefore. However, if desired, the openings may not be used and the gates could seal with the seats, although that is not the presently preferred embodiment. It will be noted that a T-slot connection can be used on the ends of the gate with corresponding T connector on the piston rods if desire.
[0068] In one embodiment, the taper angle at the cutting edge of the gates is unique. Cutting inserts may or may not be used. If desired, hard facing or case hardening process may not be used on the gates.
[0069] FIG. 8 shows a schematic of intervention package 100 that comprises CCD 10 , which may be utilized with gate valve 102 in conjunction with subsea installation 104 in substitutions for a much heavier BOP in accord with one embodiment of the invention. CCD 10 may be utilized to cut 3½ in. 13.3 lb/ft Grade E-75 drill pipe without leaving any snag after cutting in accord with Table 18, API 16A/ISO 13533 and may be utilized to cut up to 4½ IN 16.60 lb/ft drill pipe. The use of CCD 10 in place of the much heavier BOP for use in an intervention package complies with codes and standards including:
[0070] API 6A, Specification for wellhead and Christmas tree equipment, 20th Edition, October 2010;
[0071] API 16A, Specification for Drill-through equipment, 3rd Edition, June 2004;
[0072] API 16D Control Systems for Drilling Well control Equipment, 2nd Edition, July 2004;
[0073] NORSOK D-002, Well intervention equipment, Revision 2, June 2013;
[0074] DNV-OS-E101, Drilling Plant, October 2013;
[0075] ISO 13533, Drilling and production equipment—Drill-through equipment, 1st Edition, December 2001;
[0076] API 17G, Recommended practice for completion/workover risers, 2nd edition, July 2006
[0077] NACE MR0175/ISO 15156, Petroleum and natural gas industries—materials for use in H2S-containing environments in oil and gas production, 2nd Edition, October 2009.
[0078] FIG. 9 , which is another embodiment of a cutting system, namely cutting system 10 A, shows openings 64 and 66 in gates 44 , 46 which surround throughbore 12 and pipe 68 . Cutting system 10 A utilizes longer cylinder rods and housing.
[0079] It will also be seen that gate opening 64 decreases in inner diameter with distance away from seat 40 as indicated by interior surface profile 52 until coming to cutting face 74 at the bottom of upper gate 44 . Likewise, the inner diameter of gate opening 66 decreases with distance away from seat 42 as indicated by interior surface profile 54 until coming to a cutting face 76 at the top of lower gate 46 . The changes in inner diameter of the openings 64 , 66 through the gate can also be seen in FIG. 1 , FIG. 2 , and FIG. 3 .
[0080] In this embodiment, the interior or inner diameter of upper seat 40 decreases in diameter with distance away from gate 44 as indicated by interior surface profile 48 . The interior of lower seat 42 also decreases in diameter with distance away from lower gate 46 as indicated by interior surface profile 50 . The decrease in diameter of the upper and lower seats discussed above leads to the throughbore diameter at about the midpoint of the seats, which in one embodiment may be 7⅜ inches. In other words, both the seats and the gates comprise openings which are larger than the throughbore diameter in some regions and then either approach or are at the throughbore diameter, e.g. at the cutting faces and at the upper portion of upper seat 40 and the lower portion of lower seat 42 . The minimum diameter is the throughbore diameter. As discussed above, both the interior of the seats and the gates may be oval.
[0081] Upper seat seal surface 70 is recessed into housing 12 and seals with upper seat 40 . Lower seat seal surface 72 is recessed into housing 12 and seals with lower seat 42 . Face 78 is provided between first gate 44 and seat 40 . Face 80 is provided between second gate 46 and seat 42 . As discussed hereinbefore, in one embodiment the seats do not seal off throughbore 12 even when the gates are in the closed position. However, if desired, a metal to metal seal could be provided at face 78 , 80 to seal off throughbore 12 with the gates in the closed position.
[0082] In one embodiment, CCD 10 is operable to cut pipe 68 which may comprise 3½ in 13.3 lb/ft Grade E 75 drill pipe (Table 18, API 16A/ISO 13533) or 4½ IN 16.60 lb/ft drill pipe.
[0083] In summary, the present invention provides a compact cutting system or device. In one embodiment to provide a 7⅜ throughbore, the compact cutting system or device may be in the range of 40 to 50 inches in height, in the range of 65 to 75 inches at maximum width, and with a diameter in the range of 20-25 inches, with a weight in the range of 11,000 to 12,000 pounds. In one embodiment, a relatively short stroke is utilized. In one embodiment, the piston rods are at different vertical heights. The openings in the gates preferably surround the throughbore or form part of the throughbore in the open position. In the closed position, the gates may be modified to provide that they do not seal with the seats.
[0084] The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description only. It is not intended to be exhaustive nor to limit the invention to the precise form disclosed; and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims. | As compared to a BOP, a compact lightweight cutting system comprises two gates with cutters moveable in opposite directions to cut drill pipe. In one embodiment, the system comprises a relatively short stroke and utilizes relatively less hydraulic oil for subsea operation. In one embodiment, an opening through the gates surrounds the wellbore in the open position. The cutting elements are mounted within the openings. The piston rods and pistons are vertically offset with respect to each other. The compact cutting system with a gate valve can be used to substitute for a BOP to significantly reduce the size and weight required in an intervention system. | 4 |
RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 60/515,413, filed Oct. 29, 2003.
BACKGROUND
In a conventional multiplexed reverse dot blot hybridization assay protocol used in the process of detecting the presence of particular alleles in a sample, selected loci in the double-stranded genomic DNA are first amplified using pairs of forward and reverse primers, and one designated strand of each of the double-stranded amplicons is removed, for example by enzymatic digestion or magnetic separation. Only the remaining strands, preferably labeled, are placed in contact with a set of cognate probes, spotted or otherwise placed on a substrate, such as a strip of nitrocellulose, or displayed on encoded microparticles in preparation for a hybridization assay. Hybridization is typically detected based on the presence of label associated with the set of captured targets or with the corresponding probes. Decoding allows determination of the subsequences of the strands captured by particular probes, indicating that the capturing probes are complementary to such subsequences.
Removal of the designated strands is intended to improve the efficiency of capture of the remaining strands to probes, by eliminating strand-strand re-annealing, a process which competes with annealing to cognate capture probes, and would otherwise take place without strand selection and removal in the protocol.
Strands can be removed by digestion, wherein strands selected for removal are first phosphorylated, and then enzymatically digested using a digestion enzyme such as λ-endonuclease for the phosphorylated strands. Strands can also be removed by magnetic separation. Both digestion as well as magnetic separation add cost and labor to the assay protocol. A preferable alternative would be to generate single-stranded fragments from amplicons, thereby eliminating the need for digestion or magnetic separation.
Several methods are known to generate single-stranded fragments of random length from double-stranded DNA. In the conventional Maxam and Gilbert sequencing method (A. Maxam and W. Gilbert, PNAS 74, p. 560, 1977), fragments of double-stranded DNA are generated by selective chemical degradation of multiple copies of the DNA species to be sequenced. Conditions are adjusted to produce fragments of all possible lengths; that is, fragments can be separated into fractions differing from one another in length by only a single base. When ordered, the sequence of fractions with their respective terminal bases represents the sequence of the original DNA species.
E. Southern et al. have also generated random-sized single-stranded fragments from double-stranded DNA to facilitate the transfer of DNA from agarose gels for blotting on membranes for further analysis by hybridization with oligonucleotide probes, in what represents a dot blot format. Conditions are adjusted to produce fragments that are sufficiently short to minimize entanglement within the gel.
To date, no one has suggested the use of amplicon fragments without strand digestion or separation for use in reverse dot blot hybridization assay formats. Thus, there is no suggestion that, for multiplexed analysis of polymorphisms (MAP), the use of a complex mixture of highly heterogeneous target fragments is preferable to the use of a single, or at most a few, target sequences. Further, to use fragmentation for MAP, unless conditions are adjusted correctly, some or all polymorphic sites may be eliminated, or labeling may be impractical, and none of these problems or their solutions have been suggested.
One conventional method of labeling amplicons is to perform the amplification with 5′-terminally labeled primers so as to produce end-labeled amplicons. This end-labeling method requires that labeled strands remain intact because, after fragmentation, none but a small portion of the fragments containing the 5-terminus will be labeled. Therefore, a different method of labeling is needed where the amplicons are to be fragmented.
SUMMARY
A method of fragmentation of double stranded DNA is disclosed for use in nucleic acid analysis, notably in the multiplexed analysis of polymorphisms and mutations. The method produces a multiplicity of labeled sense and anti-sense fragments which are not complementary, and thus do not significantly re-anneal under conditions suitable for hybridization analysis (or capture-mediated elongation analysis) of the polymorphisms and/or mutations. The fragments display a desired or predicted length distribution. Cleavage sites can be selected such that the fragments are short, yet long enough to allow discrimination among fragments in an assay, and as a matter of statistical probability, such that the majority of fragments contain at least one labeled nucleotide to facilitate detection. That is, conditions are adjusted so as to produce a fragment length distribution which generates a selected linear density of strand labeling, by inclusion of labeled nucleotides. In an alternative embodiment, the majority of fragments are comparable in length to the length of the cognate capture probes.
Double stranded DNA (or double stranded amplicons derived from double stranded DNA by amplification) is transformed into a set of sense and anti-sense fragments by strand cleavage at a multiplicity of sites which are randomly distributed along each strand in order to produce fragments which are not fully complementary. This can be accomplished by simply cleaving at the same base on each strand. These fragments are then placed in contact, under annealing conditions, with probes which are fully complementary to at least some of the predicted fragments. Hybridization events are detected, and based on the results, the presence or absence of particular oligonucleotide segments in the sample is determined.
The advantages of this method are:
(i) eliminating the step of post-PCR strand selection;
(ii) enhancing the target capture efficiency by selecting the density of fragmentation sites so as to generate relatively short targets having minimal secondary structure and display a high effective affinity, as detailed in co-pending application, entitled: “Optimization of Gene Expression Analysis using Immobilized Capture Probes,” filed on Oct. 28, 2004, incorporated by reference.
(iii) permitting the use of both sense and anti-sense capture probes for the interrogation of polymorphic sites on both strands. This is an aspect of design which is advantageous in a multiplexed assay, because it may be desirable to use particular probes which selectively bind to either sense or anti-sense strands, to avoid cross-hybridization with non-cognate targets. See, e.g., U.S. application Ser. No. 10/847,046, filed May 17, 2004 “Hybridization-Mediated Analysis of Polymorphisms (hMAP),” incorporated by reference. Further, the inclusion of the anti-sense probe along with the corresponding sense probe enhances the capture efficiency because the anti-sense probe removes from the solution a portion of sense target thereby further reducing the degree of strand re-annealing in solution.
One can incorporate, during the PCR amplification which generates the amplicons, the label which ultimately identifies the hybridized targets. A consideration here is that the label must be incorporated with sufficient frequency during PCR such that the probability is that all the resulting fragments incorporate at least some label. Necessarily, therefore, where the fragments are shorter, the frequency of label must be higher in each of the fragments.
As an optional step, following hybridization and identification of the hybridized targets in the sample, one can verify the reliability of the results of hybridization using a capture-mediated and elongation analysis. In this step, a new set of probes is designed, some of which may be shorter than or complementary to the initial probe set used for hybridization analysis. The shorter probes would be needed in the cases where in the expected targets, there is more than one polymorphic locus (or subsequence corresponding to a polymorphic locus) along the length of the fragment. In order to achieve a reliable result in capture-mediated elongation analysis, a terminal probe nucleotide must align with each polymorphic nucleotide (“SNP”). See U.S. application Ser. No. 10/271,602, entitled “Multiplexed Analysis of Polymorphic Loci by Concurrent Interrogation and Enzyme-Mediated Detection,” filed Oct. 15, 2002, incorporated by reference.
In addition, a complementary probe may be used if it aids in avoiding cross-hybridization among targets in the set. Complementary probes would hybridize to the complementary target strand (either the sense or anti-sense strand) of the target strand hybridizing with the initial probe set.
Capture-mediated elongation analysis is desirable to increase reliability of the assay results because with hybridization analysis alone (using only an initial target set) false-positives are generated by cross-hybridization. Following the capture-mediated elongation analysis, the results can be compared with the hybridization-mediated analysis, thereby further increasing the reliability. The last comparison step can be performed using a program and software.
The foregoing methods are described below with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows stained PCR products from genomic DNA, visualized on agarose gel under UV illumination.
FIG. 2 shows labeled Class I and Class II HLA PCR products which have been processed into single stranded DNA fragments by chemical cleavage and denaturation.
FIGS. 3A–3D illustrates steps involved in carrying out a hybridization-mediated assay using the methods set forth herein.
FIG. 4 shows an illustration of intensity vs. depurination time for binding of several targets.
FIGS. 5A–5D illustrates steps involved in carrying out a capture and elongation-mediated assay using the methods set forth herein.
FIG. 6 shows a titration of threshold vs. probes for six different sense probes.
FIG. 7 shows the cumulative size distribution of the fragments resulting from the chosen DNA strand with a P cut value of 5%.
FIG. 8 shows the survival probability of two different regions of unequal length but the same ratio of fragmentable to unfragmentable bonds in the chosen DNA strand.
DETAILED DESCRIPTION
To perform the methods set forth above, a double-stranded DNA sample, for example, genomic DNA, is first isolated. Certain portions, representing loci of interest, are amplified using PCR. Thereafter, the complementary sense and anti-sense strands can be placed under conditions permitting annealing, or, they can be placed into a gel which keeps the complementary strands separated. In either case, they are eventually annealed into double-stranded DNA amplicons. In the next step, the two complementary strands are cleaved at non-complementary base pairs, to generate sense and anti-sense strands that are only partially complementary. Fully complementary strands would anneal with each other when placed under annealing conditions in contact with a probe array, thereby competing with probe annealing and affecting the assay results.
One well-known method to cleave the sense and anti-sense amplicon strands at particular bases which are not complementary is to randomly nick the purine bases on the amplicons using hydrochloric acid, thereby depurinating these bases. The nicked double stranded DNAs are then heat denatured in alkaline solution thereby generating single-stranded non-complementary DNA fragments. The greater the extent of the depurination, the shorter the length of the resulting single-stranded DNA fragments following the depurination.
As a step in the PCR amplification of double-stranded DNA, it is advantageous to incorporate the label which will ultimately be used in identifying particular strands which hybridize to a probe set. One method to accomplish this is to add labeled deoxynucleotides (or dideoxynucleotides) into the PCR reaction mix to label both amplicon strands during the reaction. Another method is to add biotinylated bases during the PCR, which are then coupled with fluorescent-labeled streptavidin to label at such bases. It is preferred to biotinylate the Cytosine rather than Adenine base nucleotides, as Adenine bases will be depurinated during the depurination step, thereby causing loss of the labeling. As noted above, the labeling frequency must be high enough to ensure that even the shortest fragments one wishes to detect have label incorporated. Labeling during the PCR is advantageous for single-stranded DNA generated by fragmentation, as otherwise each strand would need to be labeled individually in a post-PCR processing step, which would be expensive and time-consuming.
As an additional step, following the hybridization, the results can be verified or refuted to increase reliability if a capture-mediated elongation reaction, as described above, is performed on the cleaved amplicons. The capture-mediated elongation reaction can be performed using shorter or complementary probes to those in the initial set, as described above.
The Examples below further illustrate the methods set forth herein.
EXAMPLE 1
PCR Amplification
Genomic DNA isolated from human tissue and cells are used as templates in a polymerase chain reaction (PCR). Oligonucleotides flanking HLA Class I and II genes are used as forward and reverse primers for amplification of specific loci, or specific gene segments. More than one pair of primers could be used in PCR for amplification of multiple loci. In addition, primers may contain degenerate bases for priming of genomic DNA at polymorphic sites. PCR is performed according to the well-known methods.
Preferably, at least one type of ligand-labeled deoxynucleotide is added into the PCR reaction mixture, to generate amplicons where both strands are labeled. The ligand could be a fluorescent dye or a molecule such as biotin, which can be coupled to a label after the reaction.
PCR is performed using a programmable thermocycler. An aliquot of the PCR products are run on agarose or polyacrylamide gel using electrophoresis, with DNA ladders included in the gel as markers. DNAs in the gel are stained with ethedium bromide, and visualized on a UV transluminator to verify the integrity and yield of the PCR amplicons. For example, exon 2 and exon 3 of A and B loci were amplified in multiplexed PCR by using two sets of primers. Exon 2 of DR locus was amplified using one set of primers. PCR products were biotinylated on both strands with a density of more than one biotinylated nucleotide for each 20 bases of the amplicons. Aliquots of the PCR products were run on agarose gel followed by ethedium bromide staining. The stained PCR products can be visualized on the agarose gel under UV illumination, in FIG. 1 .
EXAMPLE 2
Post PCR Sample Processing
Labeled Class I and Class II PCR products are processed into single stranded DNA fragments by chemical cleavage and denaturization. Briefly, the PCR products are treated with hydrochloric acid to depurinate, as is well-known (see, e.g., M. H. Caruthers et al., in Genetic Engineering: Principles and Methods, J. K. Setlow et al., Eds. (New York: Plenum Press, 1982)). Double stranded DNA is randomly nicked at the purine bases, i.e. adenine and guanine in the presence of hydrochloric acid. The nicked double stranded DNAs are heat denatured at 94° C. in alkaline solution resulting in generation of single stranded DNA fragments. The extent of depurination directly correlates to the size of the single stranded DNA fragments.
Depurination of the PCR amplicons of the Class I and II genes was optimized to obtain small single stranded DNA fragments that, based on a probability determination, would contain at least one biotinylated nucleotide. A size distribution of the cleavage products separated on polyacrylamide gel showed that most of the single stranded DNA fragments were approximately 75 bases long. Each of the DNA fragments should, therefore, contain approximately two biotinylated nucleotides, in accordance with the conditions described in Example 1.
A time course experiment was performed to optimize depurination conditions. Biotinylated PCR products for exon 2 and 3 of the B locus were incubated with specific amounts of hydrochloric acid and incubated in a water bath for increasing periods of time, followed by addition of sodium hydroxide and heat denaturing. The chemically cleaved PCR products were run on 8% urea sequencing to separate the digested products, followed by ethidium bromide staining. The cleaved products were visualized on a UV transluminator ( FIG. 2 ), which demonstrate that the amount of small cleavage products increases as depurination time increase ( FIG. 2 ).
EXAMPLE 3
On Chip Hybridization Assay
Processed PCR products prepared as described in Example 2 were heat denatured to obtain large numbers of single stranded DNA fragments. After denaturing, the samples are snap frozen on ice to preserve DNA fragments in a single-stranded state. The DNA samples are then mixed with a hybridization buffer for on-chip hybridization to complementary oligonucleotide probes, where different probe types are each immobilized on differently encoded microparticles, and the microparticles are placed in an array on a solid substrate (a “BeadChip™”). See, e.g., U.S. application Ser. No. 10/204,799: “Multianalyte Molecular Analysis Using Application-Specific Random Particle Arrays,” filed on Aug. 23, 2002, incorporated by reference.
The hybridization conditions and the ionic strength of the hybridization buffer are conventional in the art. Preferably, on-chip hybridization is carried out in a temperature and humidity-controlled incubator, for fast and efficient reaction dynamics. See U.S. patent application: “Controlled Evaporation, Temperature Control and Packaging for Optical Inspection of Biological Samples,” Ser. No. 10/870,213, filed Jun. 17, 2004.
Following hybridization, unbound labeled DNA is removed by intensive washing. Where the oligonucleotides are bound with ligands, such as biotin, rather than fluorescent dyes, the assay chips are incubated with staining solution containing fluorescent-labeled molecules that have a high affinity for the ligands. For example, one can use fluorescently-labeled streptavidin for binding to the biotinylated DNA fragments.
If there is significant cross-hybridization, the labeled DNA targets may be captured by more than one type of probe, and associate with more than one type of encoded microparticle on the BeadChips.
As shown in FIG. 3 , a typical hMAP BeadChip assay would have four steps as follows: Step 1, PCR amplification of genomic DNAs in the presence of labeled dNTPs, such as biotinylated-dATP and biotinylated-dCTP. Both strands of the PCR products are labeled in the PCR reaction. Step 2, the labeled PCR products were depurinated in the present of hydrochloric acid followed by heat denaturing in alkaline solution. Step 3, the fragmented single-stranded DNA targets were used as targets for a BeadChip assay. Step 4, the captured targets on the beads were detected by incubation with fluorescent-labeled ligands that have high affinity to the labels, such as Cy3 conjugated streptavidin for detection of the biotinylated targets, followed by READ detection ( FIG. 3 ).
The cleavage DNA products described in Example 2 were used in a BeadChip hMAP assay. Briefly, each of the depurination treatment products, i.e., those resulting from 0, 10, 13, 15, 17, 20, 25, and >25 min depurination, was used as a target in the hMAP BeadChip assay. Hybridization intensities of the targets to a panel of sequence-specific probes were analyzed. As shown in FIG. 4 , intensity for probe A and probe C decreases as depurination time increases, suggesting increasing cleavage of long DNA targets into smaller fragments from the depurination. However, intensities for Probes B, D, E and F first increase in partial depurination, then decrease in further depurination, suggesting partial cleavage results in release of certain target sequences that were unavailable in long DNAs due to other factors, such as secondary structure of the targets ( FIG. 4 ).
EXAMPLE 4
Preparation of Custom BeadChip
DNA oligonucleotide probes used in the hybridization-mediated assay may contain a terminal reactive group, an internal spacer molecule, and a stretch of nucleotides that are complementary to target DNAs of interest. The oligonucleotide probes can be complementary to the sense strand or the antisense strand of the DNA molecules. One or the other strand is selected to reduce cross-hybridization.
After coupling DNA oligonucleotides to the color encoded microparticles, different oligonucleotide-functionalized microparticles are combined into one tube for assembly of a random planar bead array on a silicon wafer (or BeadChip). In HLA molecular typing, each BeadChip should contain multiple sense and antisense probes for specific locus of Class I and Class II molecules. BeadChips for different loci may be bound into a common chamber for hybridization reaction.
EXAMPLE 5
Capture-Mediated Elongation Analysis
As discussed above, following the hybridization-mediated analysis, results may be confirmed or refuted using capture-mediated elongation reactions. As shown in FIG. 5 , a typical eMAP BeadChip assay using chemically cleaved DNA targets should have four steps as follows: Step 1, PCR amplification of genomic DNAs. Step 2, PCR products are depurinated in the presence of hydrochloric acid followed by heat denaturing in alkaline solution. Step 3, the fragmented single-stranded DNAs are used as targets for hybridization to sequence-specific probes followed by an elongation reaction in the presence of fluorescent-labeled dNTPs, such as Cy3-labeled dATP and dCTP. Step 4, the target templates are removed by intensive washing followed by READ detection of elongated probes ( FIG. 5 ).
EXAMPLE 6
Sense and Antisense Probes in a Multiplexed HMAP Assay
The chemically cleaved DNA targets described herein can be hybridized to a panel of multiple oligonucleotide probes in multiplexed assay format, e.g., one can assay for HLA genes in such a format. In such a multiplexed assay, the oligonucleotide probes may contain capture sequences complementary to either the sense or antisense strands of target HLA subsequences. When such assay was used in screening a set of human DNA samples of known genotypes, probe signal to positive control signal ratio (the “signal ratio”) can be determined in each sample for each of the probes of the probe set. A threshold can be arbitrarily set on the signal ratio to distinguish “perfect match,” between probe and target, from “mismatch.” By binding to the complementary strand of the target DNAs, addition of antisense probes in the panel can enhance capturing efficiency of the sense probes in the multiplex hMAP assay. Experimentally, it was shown that addition of antisense probes did not reduce the capturing efficiency of any of the sense probes and in fact capturing efficiency improved when the antisense probes were added (results not shown). An assay of sense probes only is shown in FIG. 6 .
EXAMPLE 7
Modeling of DNA Fragmentation
In this example the modeling of two different aspects of the DNA fragmentation process is addressed, i.e., the fragment size distribution of single stranded DNA (of a known composition) and the survival probability of a particular stretch of DNA in the strand following fragmentation. The value of this analysis is two fold. First, it identifies how the fragment size evolves as a function of % fragmentation. Second, by modeling fragment size distribution, it provides a unique way of estimating the survival probability of a target region in the DNA strand of interest. This has important implications as far as design of capture probes are concerned because only that fraction of fragments containing the intact subsequences of interest, or those fragments allowing substantial probe-target overlap, can successfully anneal to the capture probe. Fragments with smaller mutual overlap regions denature before detection or extension takes place. Also, since fragment size distribution and the % of strands containing an uncut region of interest are both experimentally accessible quantities, this method provides a unique way of matching experimental with modeling results, possibly allowing to quantify important parameters in the model.
For the purpose of the simulation, it is assumed that the experimental fragmentation protocol outlined above generates a random distribution of polynucleotide fragments. Random fragmentation implies that each cleavable nucleotide-nucleotide bond has an equal probability, P cut , of being broken. This assumption is reasonable because the fragmentation protocol is not known to be sequence-dependent and fragments all the available A and G's in an unbiased fashion. Another assumption is that the bond breaking events are independent and hence the order in which the fragments are produced does not affect their probabilities of occurrence. Simulations were performed using a single stranded HLA B Exon 2 amplicon, which is 268 bases long. The sequence is shown below (SEQ ID NO. 1).
1 GCTCCCACTC CATGAGGTAT TTCTACACCT CCGTGTCCCG GCCCGGCCGC 51 GGGGAGCCCC GCTTCATCTC AGTGGGCTAC GTGGACGACA CCCAGTTCGT 101 GAGGTTCGAC AGCGACGCCG CGAGTCCGAG AGAGGAGCCG CGGGCGCCGT 151 GGATAGAGCA GGAGGGGCCG GAGTATTGGG CCGGAACACA CAGATCTACA 201 AGGCCCAGGC ACAGACTGAC CGAGAGAGCC TGCGGAACCT GCGCGGCTAC 251 TACAACCAGA GCGAGGCC
Methodology:
1) Given parameters P cut (P cut =% fragmentation) and strand sequence. 2) Divide the sequence into regions differentiable by bonds which can be broken and which cannot be broken by the protocol. The total number of fragmentable bonds is denoted as n F . Adjacent nonfragmentable bonds are lumped together as unfragmentable regions flanked by fragmentable bonds. 3) Create an ensemble of N sequences, each containing n F regions (fragmentable). Typicaly N=1000. 4) Generate 2 vectors of uniform random numbers, R 1 and R 2 , between 0 and 1, each of size N cut =(n F *P cut *N)/100, where N cut denotes the total number of bonds in the ensemble that are to be broken. From the first vector, determine random locations within a sequence where cuts occur. Thus, for the vector R 1 , the cut locations are calculated by evaluating the quantity (n F *R 1 ). From the second vector, the particular replicate in the ensemble which is cut, is determined as follows, (N* R 2 ). Thus, for each cut, i, to be operated on the sequence, a set of two numbers are generated (f i , n i ) where n i is the replicate number on which the cut is to be made and f i is the fragmentable bond in that replicate which is to be cut. However, each set of (f i , n i ) generated may not be unique. Thus, a particular bond on a particular replicate may be revisited during the exercise. Once a given bond is designated as broken, the repeated set (f i , n i ), defining the location of that bond, is discarded whenever it is encountered. Thus in practice the total number of bonds broken during the exercise is n cut ≦N cut . 5) The number of bases (connected lumped fragmentable regions and unfragmented regions) flanked either by broken bonds or the termini of the sequence are calculated to given the fragment size distribution.
FIG. 7 shows the cumulative size distribution of the fragments resulting from the chosen DNA strand with a P cut value of 5%. The figure illustrates that small fragments are more ubiquitous than large ones (with fragments of length less than ˜20 bases constituting 50% of the final mixture of fragments). FIG. 8 shows the survival probability of two different regions of unequal length but the same ratio of fragmentable to unfragmentable bonds in the chosen DNA strand.
It should be understood that the terms, expressions and examples used herein are exemplary only, and not limiting, and that the scope of the invention is defined only in the claims which follow, and includes all equivalents of the subject matter of the claims. Process and method steps in the claims can be carried out in any order, including the order set forth in the claims, unless otherwise specified in the claims. | A method of fragmentation of double stranded DNA is disclosed for use in nucleic acid analysis, notably in the multiplexed analysis of polymorphisms and mutations. The method produces a multiplicity of labeled sense and anti-sense fragments which are not complementary, and thus do not significantly re-anneal under conditions suitable for hybridization analysis (or capture-mediated elongation analysis) of the polymorphisms and/or mutations. The fragments display a desired or predicted length distribution. Cleavage sites can be selected such that the fragments are short, yet long enough to allow discrimination among fragments in an assay, and as a matter of statistical probability, such that the majority of fragments contain at least one labeled nucleotide to facilitate detection. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is the U.S. National Phase of International Patent Application No. PCT/US2004/16339, filed May 25, 2004 which claims the benefit of an earlier filing date under 35 U.S.C. § 120 to U.S. Provisional Application No. 60/474,158, filed May 29, 2003.
FIELD OF THE INVENTION
The present invention relates to a method and a composition for bonding and sealing components of a fuel cell and a fuel cell formed therefrom. More particularly, the present invention relates to a method and to a composition for bonding and sealing membrane, electrode assemblies, bipolar plates, and combinations of membrane electrode assemblies and bipolar plates to form rebuildable, repairable fuel cells.
BACKGROUND OF RELATED TECHNOLOGY
Although there are various known types of fuel cells, one common type of fuel cell is a proton exchange membrane (PEM) fuel cell. The PEM fuel cell contains a membrane electrode assembly (MEA) provided between two flow field or bipolar plates. Gaskets are used between the bipolar plates and the MEA to provide seals thereat. Additionally, since an individual PEM fuel cell typically provides relatively low voltage or power, multiple PEM fuel cells are stacked to increase the overall electrical output of the resulting fuel cell assembly. Sealing is also required between the individual PEM fuel cells. Moreover, cooling plates are also typically provided to control temperature within the fuel cell. Such plates are also sealed to prevent leakage within the fuel cell assembly. After assembling the fuel cell stack is clamped to secure the assembly.
Preformed gaskets have been used to seal fuel cell components, see e.g., U.S. Pat. Nos. 5,176,966 and 5,284,714. The assignee of these patents, however, describes in U.S. Pat. No. 6,495,278 that such preformed patents tend to leak over time and that adhesive bonding of a membrane electrode assembly (MEA) to an adjacent pair of separator plates of a PEM fuel cell with epoxy resins, methacrylate resins, polyurethane polymers (PUR) or aliphatic polysulfides (ALIPS) reduces leakage.
Other document patents also describe the use of adhesives for bonding and sealing fuel cell components. For example, U.S. Patent Application Publication No. US 2001/00197790 describes the injection of a thermosetting silicone rubber into cavities of a PEM fuel cell to provide a formed-in-place gasket after sealing. Moreover, International Patent Publication No. WO 02/093672 A2 describes the use of a polysiloxane composition injected into fuel cell cavities to also adhesively bond the fuel cell components.
Furthermore, U.S. Patent Application Publication No. US 2001/0044042 describes the use of a thermosetting fluorine-containing material or a thermosetting silicone as a formed-in-place gasket material placed in grooves between separator plates of a fuel cell and in grooves between separator plates and membrane electrode assemblies of a fuel cell. The material used between the separator plates and the membrane electrode assemblies is described as being adhesive to bond these components. The material used between just the separator plates is described as being non-adhesive to permit replaceability of the components upon disassembly of the fuel cell assembly.
U.S. Patent Application Publication No. US 2002/0031698 describes the use of thermosetting silicone sealant to adhesively bond fuel cell components and the use of a thermosetting fluorine-containing sealant with low shear adhesive strength to non-adhesively bong the separator plates. The later sealant is described as being useful for providing stacked fuel cell assemblies with separability and rebuildability features. The sealants are described as being placed into grooves of opposing fuel cell elements. The opposing fuel cell elements are then placed together where the sealants are heated to cure the sealants and to seal and bond the elements.
The above-discussed preformed and formed-in-place gasket techniques, however, have not provided adequate sealing, have not been feasible or practical for mass production of multiple fuel cells, or have provided sealing at the expense of repairability or replaceability by adhesively bonding the various components of a fuel cell. Particularly, preformed gaskets do not generally compensate for fuel cell component tolerances or dimensional variabilities, and the above-discussed formed-in-place gaskets have not provided adequate sealability or repairability. Thus, there is a need for improved sealing compositions and methods for providing a fuel cell having both sealing and repairability.
SUMMARY OF THE INVENTION
In one aspect of the present invention, a method for forming a disassembleable fuel cell assembly is provided. The method includes, but is not limited to, the steps of
(a) forming at least two fuel cell sub-assemblies, each of the fuel cells assemblies formed by a method comprising:
(i) providing a membrane electrode assemble and two bipolar plates; (ii) applying a first portion of a curable silicone composition to internal mating surfaces of at least one of the bipolar plates; (iii) applying a second portion of the curable silicone composition to outermost mating surfaces of at least one of the bipolar plates; (iv) aligning the membrane electrode assembly between the two bipolar plates; (v) aligning a release plate to abuttingly engage the second portion of the curable silicone composition; (vi) compressing the bipolar plates and the release plate so that the first portion of the silicone composition abuts the adjacent internal mating surface of the adjacent bipolar plate and to compress the first and second portions of the silicone composition; (vii) curing the first portion of the silicone composition to adhesively bond the adjacent internal mating surfaces; (viii) curing the second portion of the silicone composition to adhesively bond the second portion to the outermost mating surfaces; and (ix) removing the release plate to provide an externally disposed and cured silicone composition;
(b) aligning the at least two fuel cell assemblies so that the externally disposed and cured silicone composition abuts both assemblies; and (c) compressing the fuel cell assemblies to provide a repairable seal disposed between the two fuel cell assemblies.
Fuels cells formed by applying a curable composition, compressing the curable composition and then curing the curable composition have been found to offer increased leak-resistance in fuel cells as compared to the use of preformed or formed-in-place gaskets.
In another aspect of the present invention, a method for forming a fuel cell includes the step of
(a) applying a curable composition at a thickness which is compressible when cured to a first fuel cell component comprising at least one fuel cell plate; (b) mating the first fuel cell component with a second fuel cell component comprising at least one fuel cell plate; (c) compressing the first fuel cell component and the second fuel cell component with a compressive force to abuttingly engage the second fuel cell component and the curable composition; and (d) curing the curable composition to form an adhesive bond between the first and second fuel cell components.
Desirably, the step of curing the curable composition between the first and second fuel cell components is done while the first and second fuel cell components are compressed under the compressive force.
Further, the method of this aspect of the present invention may further include the steps of
(e) applying an additional curable composition at a thickness which is compressible when cured to the second fuel cell component, (f) curing the additional curable composition under the compressive force; and (g) mating thereto a third fuel cell component comprising at least one fuel cell plate without creating an adhesive bond to the third fuel cell component.
The method of the present invention may further include repeating steps (a)-(d) to form at least two fuel cells and stacking the at least two fuel cells to form a fuel cell assembly which can be disassembled at the third fuel cell component.
In another aspect of the present invention a fuel cell assembly is provided. The fuel cell includes a plurality of fuel cells each comprising at least one mating surface, the fuel cells being mated with adjacent fuel cells at the mating surfaces and each mating surface having a cured composition formed therebetween as a compressible gasket, wherein at least one of the compressible gaskets between the fuel cell is adhesively bonded only to one of the adjacent mating surfaces and the other compressible gaskets are adhesively bonded to both of the adjacent mating surfaces. Desirably, the plurality of fuel cells include proton exchange membrane fuel cells, wherein the mating surfaces are selected from the group consisting of mating surfaces of bipolar plates, mating surfaces of membrane electrode assemblies, or combinations thereof.
Desirably, the cured composition is compressible up to 35% of its thickness. Moreover, the composition is applied at a thickness is at least 0.1 mils.
Fuel cells formed in accordance with the present invention are, when placed under a compressive force, substantially leak-free when tested at an internal pressure of at least 30 psig, provided that the compressive force is greater than the internal pressure. The cured compositions of the present invention conform to its adjacent substrates to eliminate surface imperfections and/or leak-paths.
A useful composition includes a silicone composition. Desirably, the composition has low post-cure volatility and is compatible with proton exchange membranes. Further, the composition is advantageously a low-ionic silicone composition and is non-reactive with metals of group 8 of the periodic table, for example platinum.
In another aspect of the present invention, a curable composition useful in fuel cell assemblies includes
(a) polydiorganosiloxanes having curable terminal vinyl groups within the following structure:
wherein R 1 and R 2 may be the same or different, and are selected from aryl, alkyl, haloalkyl, hydride, and hydroxide; and n is an integer within the range of about 25 to about 100,000;
(b) polydiorganosiloxanes having hydride functionality within the following structure:
wherein at least one R 3 is hydrogen and the other R 3 is within R 4 , R 4 is an unsubstituted or substituted monovalent hydrocarbon group; R 5 is hydrogen, or an unsubstituted or substituted monovalent hydrocarbon; or R 3 is within R 4 , provided at least one R 5 is hydrogen; x is an integer within the range of about 3 and 10 and y is an integer within the range of 0 to about 10,000; and
(c) an addition cure catalyst;
wherein the curable composition has low post-cure volatility and is compatible with proton exchange membranes.
Desirably, the addition cure catalyst is a metal-based addition cure catalyst, wherein the metal is a group 8 metal from the periodic table, for example platinum. It is also advantageous that the curable composition is a low ionic composition, including a composition having low amounts of destructive ionics. Further, curable compositions having less than about 1,000 ppm by weight of cyclic siloxanes on a total composition basis are useful.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a fuel cell of the present invention containing a membrane electrode assembly disposed between opposed fluid-flow field plates, which are also commonly referred to as bipolar plates.
FIG. 2 is a cross-sectional view with a partial cutaway of the fuel cell of FIG. 1 showing a continuous fluid channel for the fluid-flow field plate.
FIG. 3 is a partial cross-sectional view of the continuous fluid channels of the fuel cell of FIG. 2 .
FIG. 4 is a cross-sectional view of a fuel cell having a membrane electrode assembly adhesively secured between opposed fluid-flow field plates.
FIG. 5 is a cross-sectional view of a seven-layered membrane electrode assembly of the present invention.
FIG. 6 is a cross-sectional view of a five-layered membrane electrode assembly of the present invention.
FIG. 7 is a cross-sectional view of a three-layered membrane electrode assembly of the present invention.
FIG. 8 is a cross-sectional view of two mono-polar plates joined to form a bipolar plate of a fuel cell.
FIG. 9 is a cross-sectional view of a plurality of fuel cell components.
FIG. 10 is a partial cross-sectional view of fuel cell components, one of which having a sealant composition thereon.
FIG. 11 is a partial cross-sectional view of the fuel cell components of FIG. 10 being in a compressed configuration.
FIG. 12 is a cross-sectional view of the sealant composition of FIG. 10 having a thickness.
FIG. 13 is a cross-sectional view of the sealant composition of FIG. 11 having a compressed thickness.
FIG. 14 is a depiction of an assembled fuel cell assembly having a disassembly and repairability feature according to the present invention.
FIG. 15 is a depiction of a disassembled fuel cell assembly having a disassembly and repairability feature according to the present invention.
FIG. 16 is a schematic depiction of an assembly for forming fuel cells in accordance with the present invention.
FIG. 17 is a schematic depiction of a fuel cell assembly of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a low volatile, low ionic silicone composition for sealing and/or bonding fuel cell components. The silicone composition contain an addition cure or hydrosilation catalyst that is compatible with the fuel cell assembly in that it does not poison or otherwise adversely effect the catalyst contained within the fuel cell assembly. Furthermore, methods of the present invention include using the inventive compositions as a combination of a cure-in-place sealant and a formed-in-place sealant to provide enhance sealing and bonding while providing disassembly and repairability to the fuel cell assembly.
As used herein, the phrase “cured-in-place” and it variants refer to a composition applied to the surface of one component and cured thereat. Sealing is achieved through compression of the cured material during assembly of the one component with another component. The composition is typically applied by tracing machines in precise patterns. As used herein, the phrase “formed-in-place” and its variants refer to a composition that is placed between two assembled components and is cured to both components.
The combination of the cure-in-place and formed-in-place techniques, for example applying and curing as formed-in-place and sealing as cured-in-place, used in conjunction with the inventive composition of the present invention offers enhanced sealing because both adhesion and compression is used to provide sealing. This combination offers enhanced sealing because, among other things, the mechanical compression obviates the sealing concerns at the knit lines or other dispensing variations of the sealant in fuel cell assemblies. This combination of techniques not only offers enhanced sealing over dimensional variations due to sealant dispensing techniques, but also offers enhanced sealing as it eliminates dimensional variations in the components of the fuel cells. Knit lines are junctions of applied sealant materials. Sealants are typically applied as an elongate bead, elongate strip or elongate thread of material. A knit line is formed where application of the sealant material starts and ends, typically in abutting relationship to one and the other. At the knit line the amount of material or the corresponding height of material is greater as compared to other portions of applied material. In automatic processes, such as robotic tracing or screen printing processes, knit lines and dispensing variations are often located at a similar location or locations on like substrates or components. As the components are subsequently stacked to form an assembly of multiple components, the dimensional variability associated with the knit lines or dispensing variations of individual components are magnified.
FIG. 1 shows, schematically, the basic elements of an electrochemical fuel cell, such as fuel cell 10 . Electrochemical fuel cells convert fuel and oxidant to electricity and reaction product. The fuel cell 10 includes a membrane electrode assembly (“MEA”) 12 consisting of a solid polymer electrolyte or ion exchange membrane 14 disposed between two electrodes 16 A, 16 C. The electrodes 16 A and 16 C are typically formed of porous, electrically conductive sheet material, such as carbon fiber paper. The present invention is not, however, limited to the use of carbon fiber paper and other materials may suitably be used. The MEA 12 contains a layer of catalyst (not shown), typically in the form of finely comminuted platinum, at each membrane/electrode interface 18 A, 18 C to induce the desired electrochemical reaction. The electrodes 16 A, 16 C are electrically coupled to provide a path for conducting electrons between the electrodes to an external load (not shown).
At anode 20 , the fuel permeates the porous electrode material of electrode 16 A and reacts at the catalyst layer (not shown) at membrane/electrode interface 18 A to form cations, which migrate through the ion exchange membrane 14 to cathode 22 . At the cathode 22 , oxygen-containing gas reacts at the catalyst layer (not shown) at membrane/electrode interface 18 C to form anions. The anions formed at the cathode 22 react with the cations to form a reaction product.
In electrochemical fuel cells employing hydrogen as the fuel and oxygen-containing air (or substantially pure oxygen) as the oxidant, the catalyzed reaction at the anode 20 produces hydrogen cations (protons) from the fuel supply. The ion exchange membrane 14 facilitates the migration of hydrogen ions from the anode 20 to the cathode 22 . In addition to conducting hydrogen ions, the ion exchange membrane 14 isolates the hydrogen-containing fuel stream from the oxygen-containing oxidant stream. At the cathode 22 , oxygen reacts at the catalyst layer (not shown) at membrane/electrode interface 18 C to form anions. The anions formed at the cathode 22 react with the hydrogen ions that have crossed the ion exchange membrane 14 to form liquid water as the reaction product. The anode and cathode reactions in hydrogen/oxygen fuel cells are shown in the following equations:
Anode reaction: H 2 →2H + +2e − (I)
Cathode reaction: ½O 2 +2H + +2e − →H 2 O (II)
The MEA 12 is disposed between two electrically conductive plates, such as fluid-flow field plates or bipolar plates 24 A, 24 C, each of which has at least one flow passage 26 A, 26 C contained therein. These fluid-flow field plates or bipolar plates 24 A, 24 C are typically formed of compressed, exfoliated graphite; porous graphite; stainless steel or graphite composites. The plates may be treated to effect surface properties, such as surface wetting, or may be untreated. The present invention is not, however, limited to the use of such materials for use as the bipolar plates and other materials may suitably be used. The flow passage 26 A directs the fuel, as indicated by arrows 28 A, to the anode 20 on the fuel side. The flow passage 26 C directs the oxidant, as indicated by arrows 28 C, to the cathode 22 on the oxidant side.
The bipolar plates 24 A, 24 C may have additional flow passages 27 opposed to flow passages 26 A and 26 C. The additional flow passages 27 serve as fuel or oxidant flow paths for an adjoining fuel cell (not shown). The plates 24 A and 24 C are referred to as bipolar because they have opposed flow passages, for instance flow passages 26 A and 27 .
In a single cell arrangement, fluid-flow field plates are provided on each of the anode and cathode sides. The plates act as current collectors, provide support for the electrodes, provide access channels for the fuel and oxidant to the respective anode and cathode surfaces, and provide channels in some fuel cell designs for the removal of water formed during operation of the cell.
FIG. 2 is a cross-sectional view of a partial cutaway of the fuel cell 10 taken along the 2-2 axis showing fluid-flow field plate 24 C. The fluid-flow field plate 24 C includes a single continuous fluid-flow channel 26 C which has a fluid inlet 30 C and a fluid outlet 32 C. Fluid inlet 30 C is connected to a source of oxidant (not shown). Continuous flow channel 26 C traverses in a plurality of passes a major central area of fluid-flow field plate 24 C, which corresponds to the electrocatalytically active region of the cathode 22 . Fluid field flow plate 24 A has a similarly connected fluid-flow channel 26 A, but its fluid inlet is connected to a fuel source.
As depicted in FIG. 3 , the fluid-flow channels 26 A, 26 C are separated by walls 34 A, 34 C, respectively. The fluid-flow channels 26 A, 26 C are typically 1.5 mm deep and 1 to 1.5 mm wide and extend to cover the electrode area of the fuel cell 10 . The walls 34 A, 34 C are typically 1 to 1.5 mm inch thick. The fluid-flow channels 26 A, 26 C may be formed by a mechanical deformation process, such as stamping, pressing, milling, molding and the like. A compression plate bearing a relief pattern of the fluid-flow channel is useful to impress the pattern in a flexible graphite sheet.
As depicted in FIG. 4 , a composition 36 may be used to securably seal and/or bond the elements of the MEA 12 ′. For example, composition 36 can adhesively and securably seal and/or bond the fluid-flow field plates or bipolar plates 24 A, 24 C to prevent leakage of the reactants (fuel and oxidant) and products (water) from the MEA 12 ′. Alternatively, as discussed below, composition 36 may not be adhesively secured to abutting fuel cell components, such as field flow plates 24 A and 24 C. Further, as depicted in FIG. 4 , composition 36 encapsulates the ends or edges 35 of MEA 12 ′. The present invention, however, is not so limited and other sealing techniques may be used to seal fuel cell edges.
Moreover, a composition, such as an adhesive composition, may be used to secure the various elements of MEA's. For example, a seven-layered MEA 12 ′ is cross-sectionally depicted in FIG. 5 . Catalyst layers 17 A and 17 C are disposed on opposed sides of the ion exchange membrane 14 . Compositions 19 A and 19 C sealably join electrodes 16 A and 16 C, respectively. MEA 12 ′ is not, however, limited to a seven-layered structure. A five-layered MEA 12 ′ is depicted in FIG. 6 . The five-layered MEA 12 ′ of FIG. 6 has the ion exchange membrane 14 with catalyst layers 17 A and 17 C and compositions 19 A and 19 C disposed thereover or disposed over portions of the catalyst layers 17 A and 17 C. Further, a three-layered MEA 12 ′ is depicted in FIG. 7 as having the ion exchange membrane 14 and opposed catalyst layers 17 A and 17 C. The three-layered MEA 12 ′ of FIG. 7 does not have a sealing gasket or sealing material, such as compositions 19 A and 19 C as shown in FIGS. 5 and 6 .
Further, the present invention is not limited to the use of bipolar plates, which have opposed field flow passages. For example as depicted in FIG. 8 , mono-polar plates 29 and 29 ′, which have only one set of field flow passages, may suitably be used. Such mono-polar plates 29 and 29 ′ may be adhesively or otherwise mechanically joined. For example, composition 31 may adhesively join mono-polar plates 29 and 29 ′. Composition 31 may releasably join the mono-polar plates 29 and 29 ′. Additionally, composition 31 may be a conductive composition that permits electrical conductivity therethrough.
Two or more fuel cells 10 can be connected together, generally in series but sometimes in parallel, to increase the overall power output of the assembly. In series arrangements, one side of a given plate serves as an anode plate for one cell and the other side of the plate can serve as the cathode plate for the adjacent cell. Such a series connected multiple fuel cell arrangement is referred to as a fuel cell stack (not shown), and is usually held together in its assembled state by tie rods and end plates. The stack typically includes manifolds and inlet ports for directing the fuel and the oxidant to the anode and cathode flow field channels.
As depicted in FIG. 9 , a plurality of fuel cells 10 or a plurality of MEA's 12 may be joined together. For example, composition 36 , 36 ′ can securably seal and/or bond the fluid-flow field plates or bipolar plates 24 A, 24 C, which are shown as plate 25 having both flow passages 26 A and 26 C. The composition 36 and 36 ′ may be the same or different.
As depicted in FIG. 10 , the compositions of the present invention, for example composition 36 , may be applied to a fuel cell component 31 . Fuel cell component 31 may be any of the above-described structures, for example a bipolar plate, a mono-polar plate, a MEA, different elements of a MEA, a coolant plate or a separator plate. As discussed in further detail below, components 31 and 31 ′ may be pressed against one and the other to have composition 36 abuttingly disposed between mating surfaces 33 and 33 ′ of fuel cell components 31 and 31 ′, respectively. Composition 36 may then be cured to adhesively join fuel cell components 31 and 31 ′, as depicted in FIG. 11 .
The composition 36 of FIG. 10 has a thickness or height X as depicted in FIG. 12 and has a compressed thickness or height X′ as depicted in FIG. 13 , where X′ is less than X. Desirably, composition 36 is resiliently compressible up to about 50% of its thickness, i.e., X′ is up to about 50% of X. Compositions with other resilient compressibilities may suitably be used. For example, compositions with resilient compressibilities from about 1% to about 50% are useful. Also useful are compositions having a resilient compressibility from about 5% to about 35%. Desirably, the composition has a resilient compressibility from about 10% to about 25%. As used herein, compressibility of a composition refers to the ability of the composition, that is substantially dimensionally stable on a substrate, to dimensionally reduce under force while maintaining its overall structure, sealing and adhesive characteristics. In other words, the composition may be squeezed to some degree while still maintaining its ability to sealingly join substrates. The composition 36 of FIGS. 10 and 12 is shown as a round bead, but the present invention is not so limited, and other applied shapes may be suitably be used. Further, the composition 36 of FIGS. 11 and 13 is shown compressed as an elliptical shape, but other compressed shaped may suitably be used.
The amount of thickness X of composition 36 applied to a fuel cell component varies, and the composition 36 may be applied at a thickness of up to about 500 mils (about 13 mm) or greater. Desirably, the composition is applied at a thickness of about 0.1 mils to about 500 mils (or, about 0.0025 mm to about 33 mm). More desirably, the composition is applied from about 1 mil to about 40 mils (or, about 0.025 mm to about 1.0 mm), including thicknesses from about 1 mil to about 5 mils (or, about 0.025 mm to about 0.13 mm).
As depicted in FIG. 14 , the compositions of the present invention are applied to fuel cell components to adhesively secure and seal the components and applied to certain fuel cell components to just seal. For example, fuel cell assembly 100 includes a plurality of fuel cell modules 46 A through 46 F, which represent the plurality of fuel cells elements as described above, having compositions for sealing and/or bonding the modules. Fuel cell modules 46 A through 46 C are adhesively secured to one and the other via composition 40 , and fuel cell modules 46 D through 46 F are adhesively secured to one and the other via composition 40 . Fuel cell modules 46 C and 46 D are sealed via composition 42 , but not adhesively secured. In other words, composition 42 is adhesively bonded to only one of the fuel cell modules, for example fuel cell module 46 D, to provide a sealing function as a gasket upon mechanical securement of the fuel cell modules to form the fuel cell assembly 100 . Because the composition is not adhesively bonded to both fuel cell modules, the fuel cell modules 46 C and 46 D are separable from one and the other, as depicted in FIG. 15 . Moreover, the fuel cell modules may have a mating surface 44 or groove for facilitating placement and compression of the silicone compositions of the present invention.
FIG. 16 depicts an apparatus 50 useful for producing the fuel cell assemblies of the present invention. Fuel cell components 52 , 54 and 56 have compositions 58 disposed thereon. The composition 58 may be robotically dispensed, screen printed or dispensed by other methods onto the fuel cell components 52 , 54 and 56 . The fuel cell components are then placed onto the base 60 of apparatus 50 . The fuel cell components 52 , 54 and 56 are aligned and compressed to a desired height or thickness. Compression is accomplished by controllably forcing down top plate 62 toward the bottom plate 60 . The top plate 62 is then secured to control the desired height or thickness of the fuel cell components. Any suitable means may be used to clamp the top plate 62 , for example a nut/bolt assembly 64 may be used. The compositions 58 are then cured while under compression within apparatus 50 . Desirably, top plate 62 is made from a releasable material or has a layer of releasable material associated with its surface 68 . Alternatively, a layer of releasable material (not shown) may be placed between the top plate 62 and the fuel cell component 52 , provides that it covers the composition deposited thereat. Any suitable release material, such as Teflon®, may suitably be used.
After curing, cured compositions 58 are adhesively secured to adjacent fuel cell components, such as fuel cell components 52 and 54 and fuel cell components 54 and 56 . The composition 58 ′ cured between the release layer and the fuel cell component 52 is adhesively secured only to fuel cell component 52 . This cured composition 58 ′, after being released from the release layer, allows the fuel cell assemblies of the present invention to have repairability and rebuildability. Thus, this cured composition 58 ′ acts as a cured-in-place gasket while the other cured compositions 58 act as formed-in-place gaskets having the compressingly sealable features of cured-in-place gaskets. The fuel cell component 52 with the cured composition 58 ′ may be mated to any of the above-described fuel cell components or structures, for example a bipolar plate, a mono-polar plate, a MEA, different elements of a MEA, a coolant plate or a separator plate or alternatively, may be mated to fuel cell top or bottom plates, which are described below in conjunction with FIG. 17 .
As depicted in FIG. 17 , fuel cell modules 82 are formed into a fuel cell assembly 80 by aligning and stacking the fuel cell modules 82 between fuel cell top plate 84 and fuel cell bottom plate 86 . Compressive force is applied and maintained on the fuel cell modules 82 to mechanically compress the compositions of the present invention (not shown) to seal any leak paths of fuel cell assembly 80 . As discussed above, at least one of the fuel cell modules 82 advantageously have a repairable and/or rebuildable sealant composition. One means for compressing the fuel cell assembly 80 is depicted in FIG. 17 as nut and bolt assemblies 88 . Other means for compressing and maintaining some compressive force may suitably be used.
Desirably, the fuel cell assemblies or fuel cell modules of the present invention are substantially leak-free up to an internal pressure of about 60 psig, provided that the assemblies or modules are clamped together at a force greater than internal pressure. Desirably, the assemblies or modules are substantially leak-free up to an internal pressure of about 30 psig when clamped with a greater compressive force. Lower leak-free, internal pressures of about 7 to about 15 psig, which are typical operating pressures of PEM fuel cells, may be used with the present invention, but higher leak-free pressures are preferred.
Compositions useful with the present invention include silicone compositions, the cured elastomers of which having improved adhesive and sealing properties for use in fuel cells. The compositions include a reactive silicone component, where the silicone component cures by way of an addition cure mechanism. An addition cure catalyst or hydrosilation catalyst is also provided.
As used herein, “addition curable silicone component” includes addition curing silicone fluids curable under elevated temperature or room temperature conditions. Such polymers are capable of curing in the presence of an addition cure catalyst at elevated temperature conditions, such as about room temperature or greater, but less than about 200° C. Desirably, the polymers are capable of curing in the presence of an addition cure catalyst at temperatures elevated from room temperature, for example from about 50° C. to about 100° C.
The addition curable silicone component of the present invention contains functional groups capable of undergoing addition reactions in the presence of an addition cure catalyst. Typically, the addition curable silicone component includes, for example, polydiorganosiloxanes having terminal vinyl groups that are curable, together with polydiorganosiloxanes having, for example, hydride functionality available for reaction to form an elastomer.
The vinyl-terminated polydimethylsiloxanes may be used in an amount within the range of about 25% to about 90% by weight of the composition, such as about 40% to about 80% by weight.
Examples of the vinyl-terminated polydimethylsiloxanes may be found within the following structure I:
where R 1 and R 2 may be the same or different, and are selected from aryl, alkyl, haloalkyl (such as triflouropropyl), hydride, hydroxide and the like; and n is an integer between about 25 and 100,000.
The hydride-functionalized polydimethylsiloxanes should be present in an amount within the range of about 1% to about 15% by weight of the total composition, such as about 3% to about 10% by weight.
Examples of the hydride-functionalized polydimethylsiloxanes may be found within the following structure II:
where at least one R 3 is hydrogen and the other R 3 is within R 4 , R 4 is an unsubstituted or substituted monovalent hydrocarbon group exemplified by alkyl groups, such as methyl, ethyl, propyl and butyl groups; cycloalkyl groups, such as cyclopentyl and cyclohexyl groups; alkenyl groups, such as vinyl and allyl groups; and aryl groups, such as phenyl and tolyl groups; as well as those substituted groups obtained by replacing at least a portion of the hydrogen atoms in the hydrocarbon groups with electron withdrawing groups, such as halogen atoms, cyano groups and the like; R 5 is hydrogen, or an unsubstituted or substituted monovalent hydrocarbon group exemplified by alkyl groups, such as methyl, ethyl, propyl and butyl groups; cycloalkyl groups, such as cyclopentyl and cyclohexyl groups; alkenyl groups, such as vinyl and allyl groups; and aryl groups, such as phenyl and tolyl groups; as well as those substituted groups obtained by replacing at least a portion of the hydrogen atoms in the hydrocarbon groups with electron withdrawing groups, such as halogen atoms, cyano groups and the like; or R 3 is within R 4 , provided at least one R 5 is hydrogen; and x is an integer within the range of about 3 and 10 and y is an integer within the range of 0 to about 10,000.
In the present invention, the vinyl-terminated polydimethylsiloxanes can have viscosities that range from about 100 cst (or centistokes) to about 400,000 cst, desirably from about 4,000 cst to about 50,000 cst. The hydride-functionalized polydimethylsiloxanes can have viscosities that range from about 5 cst to about 1,000 cst, desirably from about 20 cst to about 100 cst.
Desirably, the silicone compositions of the present invention have a low, post-cure volatility. As used herein, the phrase “low post-cure volatility” and its variants refer to compositions having a low migration of volatile species from the cured composition to adjoining or proximal substrates. One group of materials that potentially migrate from cured compositions are cyclic siloxanes. Such compounds can potentially migrate into fuel cell components or substrates and can effect the electrical properties of the components or substrates, as cyclic siloxanes are non-conductive. Desirably, compositions of the present invention have low, post-cure volatilities as indicated by having less than about 1,000 wppm (parts-per-million by weight) of cyclic siloxanes. More desirably, compositions of the present invention have less than about 300 wppm of cyclic siloxanes. Even more desirably, compositions of the present invention have less than about 50 wppm of cyclic siloxanes.
Further, the silicone compositions of the present invention are low ionic compositions. As used herein the term “ionics” and its variants refer to materials that are water-extractable or leachable from cured compositions. Such ionics can lead to buildup of corrosion products with the fuel cell. Further, certain ionics are destructive to fuel cells as they poison the fuel cell catalyst. Such destructive ionics include, but are not limited to, water-extractable compounds of or containing sulfur; including sulfides, sulfites and sulfates; phosphorus, including phosphates; nitrogen, including nitrides, amides, amines and hydrazides; tin, lead and arsenic. Desirably, the compounds of the present invention have less than about 20 wppm of destructive ionics or destructive ionic compounds. More desirably, the compounds of the present invention have less than about 5 wppm of destructive ionics or destructive ionic compounds. Additionally, the total ionics or amount of total ionic materials in the composition of the present invention should be less than 20 wppm and desirably less than about 5 wppm. Non-limiting examples of ionic materials include water-extractable compounds of or containing aluminum, barium, bromine, calcium, chromium, chloride, copper, fluorine, iron, lead, lithium, magnesium, manganese, nitrogen, phosphorous, potassium, sodium, strontium, tin and zinc.
The silicone compositions of the present invention may also include certain fillers for example, lithopone, zirconium silicate, hydroxides, such as hydroxides of calcium, aluminum, magnesium, iron and the like, diatomaceous earth, carbonates, such as sodium, potassium, calcium, and magnesium carbonates, oxides, such as zinc, magnesium, chromic, cerium, zirconium and aluminum oxides, calcium clay, fumed silicas, treated silicas, precipitated silicas, untreated silicas, graphite, synthetic fibers and mixtures thereof, provided that the fillers do not contain significant amounts of water-extractable ionic materials.
The filler may be used in an amount within the range of about 1% to 70% by weight of the total composition, such as about 10% to about 50% by weight.
The inventive silicone compositions also include an addition cure or hydrosilation catalyst. Suitable addition cure catalysts that can be used with the present compositions include group 8 metal-based catalysts, such as but not limited to, platinum-based or rhodium-based catalysts. Desirably, a platinum-based catalyst is used, such as platinum-siloxane complex commercially available from Bayer Corporation under the trade designation BAYSILONE U catalyst Pt/L (CAS 73018-55-0). Catalysts which may interfere with the fuel cell catalyst should be avoided. For example, tin-based catalysts should be avoided.
The addition cure catalyst should be used in an amount within the range of about 0.001% to about 1% by weight of the total composition.
Other additives can also be incorporated into the inventive compositions, provided they do not adversely affect the ability of the compositions to seal or bond fuel cell components or to otherwise adversely affect the performance of the fuel cell. For example, an adhesion promoter can be added to the inventive compositions. Such an adhesion promoter can include, for example, octyl trimethoxysilane (commercially available from Witco Corporation, Greenwich, Conn. under the trade designation A-137), glycidyl propyl trimethoxysilane (commercially available from Witco under the trade designation A-187), methacryloxypropyl trimethoxysilane (commercially available from Witco under the trade designation A-174), vinyl trimethoxysilane, methyltrimethoxysilane, vinyltrimethoxysilane, methyltriethoxysilane, vinyltriethoxysilane, enoxysilanes, tetraethoxysilane and combinations thereof. Desirably, the adhesion promoter is glycidyl propyl trimethoxysilane, vinyl trimethoxysilane and combinations thereof.
The adhesion promoters, when present, may be used in an amount within the range of about 0.05 to about 2% by weight of the total composition.
The silicone compositions of the present invention may also include additional crosslinkers. The additional crosslinkers are those capable of reacting with vinyl-terminated and/or hydride-functionalized polydimethylsiloxanes. For instance, trimethylsilyl-terminated hydrogenmethyl dimethyl siloxane copolymer with two or more hydrides per molecule (commercially available from PPG Industries as MASIL XL-1) is appropriate for use herein. Other conventionally known crosslinkers can also be used with the present compositions provided they are able to crosslink the present compositions through an addition cure mechanism without adversely affecting the adhesive and sealant properties of the fuel cell assembly.
In addition, to modify the dispensing properties through viscosity adjustment, a thixotropic agent may also be included. The thixotropic agent may be used in an amount within the range of about 0.05 to about 25% by weight of the total composition. Examples of such a thixotropic agent include reinforcing silicas, such as fused or fumed silicas, and may be untreated or treated so as to alter the chemical nature of their surface. Virtually any reinforcing fused, precipitated or fumed silica may be used.
Examples of such treated fumed silicas include polydimethylsiloxane-treated silicas and hexamethyldisilazane-treated silicas. Such treated silicas are commercially available, such as from Cabot Corporation under the tradename CAB-O-SIL ND-TS and Degussa Corporation under the tradename AEROSIL, such as AEROSIL R805.
Of the untreated silicas, amorphous and hydrous silicas may be used. For instance, commercially available amorphous silicas include AEROSIL 300 with an average particle size of the primary particles of about 7 nm, AEROSIL 200 with an average particle size of the primary particles of about 12 nm, AEROSIL 130 with an average size of the primary particles of about 16 nm; and commercially available hydrous silicas include NIPSIL E150 with an average particle size of 4.5 nm, NIPSIL E200A with and average particle size of 2.0 nm, and NIPSIL E220A with an average particle size of 1.0 nm (manufactured by Japan Silica Kogya Inc.).
Hydroxyl-functional alcohols are also well-suited as the thixotropic agent, such as tris[copoly(oxypropylene)(oxypropylene)]ether of trimethylol propane, and [H(OC 2 H 6 ) x (OC 2 H 4 ) y —O—CH 2 ] 3 —C—CH 2 —CH 3 , where x and y are each integers that may be the same or different and are within the range of about 1 to about 8,000, and is available commercially from BASF Wyandotte Corp., Wyandotte, Mich. under the tradename PLURACOL V-10.
The invention being thus described, it will be clear to those persons of skill in the art that many variations exist, which are not to be regarded as a departure from the spirit and scope of the invention. All such variations are intended to be within the scope of the claims. | A method for forming a disassembleable fuel cell assembly includes the steps of (a) forming at least two fuel cell assemblies, each of the fuel cells assemblies formed by a method including the steps of (i) providing a membrane electrode assemble and two bipolar plates; (ii) applying a first portion of a curable silicone composition to internal mating surfaces of at least one of the bipolar plates; (iii) aligning the membrane electrode assembly between the two bipolar plates; (iv) compressing the bipolar so that the first portion of the silicone composition abuts the adjacent internal mating surface of the adjacent bipolar plate; (v) curing the first portion of the silicone composition to adhesively bond the adjacent internal mating surfaces; and (vi) further compressing the bipolar plates to compress the cured first portion of the silicone composition to mechanically seal the adjacent mating surfaces against surface imperfections and/or leak paths; (vii) applying a second portion of the curable silicone composition to the outermost mating surfaces of at least one of the bipolar plates; (viii) aligning an additional bipolar plate with the outermost mating surfaces; (ix) curing the second portion of the curable silicone composition without adhering to the mating surface of the additional bipolar plate; and (b) aligning the at least two fuel cell assemblies so that the externally disposed cured silicone composition abuts both assemblies; and (c) compressing the fuel cell assemblies to provide a repairable seal disposed between the two fuel cell assemblies. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of Japanese Patent Application No. 2007-263905 filed Oct. 10, 2007 which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a display panel having pixels arranged in a matrix shape, and to detecting defects in such a display panel.
BACKGROUND OF THE INVENTION
[0003] At the fabrication stage of an active matrix type display, rapid detection of defects is an effective way of improving yield. Cause analysis can be started at an early stage, and as well as being in place at an early stage in process correction, it is also useful in preventing a substrate that has defects progressing to subsequent stages, thus avoiding wasteful fabrication.
[0004] Japanese Patent Publication 2002-221547A discloses an example of introducing an array test in a manufacturing process for a liquid crystal panel. This document shows inspection means for electrically inspecting transistors arranged on a thin film transistor substrate (TFT substrate) used in the liquid crystal panel before the TFT substrate is glued to an opposing substrate. In this way, it is easy to detect defects on the TFT substrate.
[0005] Here, among the defects, there can be some that arise as a result of the gluing together of a TFT substrate with no defects and an opposing substrate with no defects. There is an increase in the causes of defects with the increase in number of transistors accompanying increase in size of the TFT substrate and increase in number of pixels. The probability of defects arising in a TFT with no defects in subsequent processing is therefore increased. For this reason, it is desirable for electrical inspection to be carried out not only for a TFT substrate but also at the final stages of panel fabrication.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a method of detecting defects in a display panel having pixels arranged in a matrix form, wherein each pixel includes a static memory and emits light according to data stored in the static memory, data is written to the static memory of each pixel, followed by reading of data stored in the static memory, and whether or not there is a defective pixel is detected by comparing the written data with the read data.
[0007] It is also suitable to understand the positions of defective pixels as a map.
[0008] The present invention is also directed to a display panel having pixels arranged in a matrix form, wherein each pixel includes a static memory and emits light according to data stored in the static memory, externally supplied data being written to the static memory of each pixel, followed by reading of data stored in the static memory, and externally outputting the read data.
[0009] It is also appropriate to perform the writing of data to the static memory by sequentially supplying data on a data bus to data lines provided for each pixel row, and to perform reading of data from the static memory by sequentially reading out data on the data lines provided for each pixel row to the data bus.
[0010] It is also appropriate for a pixel region where pixels are arranged in a matrix form to be set large compared to a display region for a single screen It is also appropriate to be able to set the display region to an arbitrary position inside the pixel region.
[0011] It is also appropriate for the display region to be sequentially changed to a plurality of different positions every predetermined frame.
[0012] It is also appropriate to have a defect information memory for storing information about positions where defects have occurred, and set the position of the display region based on positions where defects have occurred stored in the defect information memory.
[0013] It is also appropriate for a plurality of the pixels to be collected together to form a unit pixel for dividing and displaying data for a single pixel portion.
[0014] It is also appropriate for a plurality of pixels forming the unit pixel to have respectively different display brightness.
[0015] It is also appropriate for a plurality of pixels forming the unit pixel to have respectively different surface areas.
[0016] It is also appropriate for a plurality of pixels forming the unit pixel to have the same surface area and drive currents of differing magnitudes.
[0017] It is also appropriate for writing of data to the static memory to be carried out by sequentially supplying data to a data line provided for each pixel row, for reading of the data from the static memory to be carried out by sequentially reading out data on the data line provided for each pixel row, and for a comparator for acquiring and storing data on a data line, then comparing stored data with data on the data line and storing a comparison result, and further outputting the comparison result to the data line, to be provided on each data line.
[0018] According to the present invention, pixel defects are detected by writing data to a static memory provided in a pixel and then reading the data. As a result, it is possible to effectively carry out defect detection at a stage subsequent to fabrication of each pixel of a display panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows the structure of a pixel circuit used in embodiments;
[0020] FIG. 2 shows a structural example for detecting defective pixels of a display panel of the embodiments;
[0021] FIG. 3 is a drawing showing positions of defective pixels;
[0022] FIG. 4 is a drawing showing a system for inspection;
[0023] FIG. 5 is a drawing showing a pixel region and a display region;
[0024] FIG. 6 is a drawing showing a structural example of a unit pixel;
[0025] FIG. 7 shows a structural example for detecting defective pixels of a display panel of the embodiments;
[0026] FIG. 8 shows a structural example for detecting defective pixels of a display panel of the embodiments;
[0027] FIG. 9 shows a structural example for detecting defective pixels of a display panel using a comparator;
[0028] FIG. 10 is a timing chart for the structure of FIG. 8 ;
[0029] FIG. 11 is a drawing showing another structure for a pixel circuit; and
[0030] FIG. 12 is a drawing showing an I-V curve for an organic EL element.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Embodiments of the present invention will be described in the following based on the drawings. FIG. 1 shows one example of a pixel 10 having a one-bit static memory included three transistors and two organic EL elements.
[0032] Cathodes of a first organic EL element 1 that contributes to light emission and a second organic EL element 3 that is shielded or the like and does not contribute to light emission are connected to a cathode electrode 9 that is common to all pixels and to which power supply voltage VSS is supplied. An anode of the first organic EL element 1 is connected to the drain terminal of a first drive transistor 2 , while the anode of the second organic EL element 3 is connected to a drain of a second drive transistor 4 . A source terminal of the first drive transistor 2 and a source terminal of the second drive transistor 4 are connected to a power supply line 8 common to all pixels and to which power supply voltage VDD is supplied. A gate terminal of the first drive transistor 2 is connected to a source terminal of a gate transistor 5 and to a connection point of the second organic EL element 3 and the second drive transistor 4 , while a gate terminal of the second drive transistor 4 is connected to a connection point of the first organic EL element 1 and the first drive transistor 2 . The gate terminal of the gate transistor 5 is connected to a gate line 6 , while the drain terminal of the gate transistor 5 is connected to the data line 7 .
[0033] If the gate line 6 is write selected (Low voltage supplied so that the on resistance of the gate transistor 5 becomes low compared to the on resistance of the second drive transistor 4 ) a high or low digital signal supplied to the data line 7 is fed to the gate terminal of the first drive transistor 2 . If data is Low, the first drive transistor 2 is turned on, and current flows in the first organic EL element 1 , emitting light. Since as a result of this the anode potential of the first organic EL element 1 rises to the power supply potential VDD, the second drive transistor 4 is turned off and the anode potential of the second organic EL element 3 , that is the gate potential of the first drive transistor 2 , falls to close to the cathode potential VSS. Even if the gate line 6 is unselected and the gate transistor 5 is off, the gate potential of the first drive transistor 2 is held at the cathode potential VSS, and so the first organic EL element 1 can continue to emit light.
[0034] If data is High, the first drive transistor is turned off, and so current no longer flows in the first organic EL element 1 and it is turned off. Because the anode potential of the first organic EL element 1 is lowered to the cathode potential VSS, the second drive transistor 4 is turned on. The anode potential of the second organic EL element 3 rises to the power supply potential VDD, and the gate potential of the first drive transistor 2 is held at the power supply potential, which indicates that the gate line 6 is unselected, and even if the gate transistor 5 is off the first organic EL element 1 can be kept off.
[0035] In this manner, the pixel 10 holds digital data that has been written once, and so it is not necessary to periodically repeat a write operation in order to maintain the same data.
[0036] Also, if the data line 7 is pre-charged to Low and the gate line 6 is read selected (a Low voltage higher than that causing the on resistance of the gate transistor 5 to be larger than the on resistance of the second drive transistor 4 is applied), digital data written to the pixel 10 can be read out to the data line 7 . When the gate terminal of the first drive transistor 2 is being held High, the data line 7 is pre-charged to Low, and if the gate line 6 is read selected current flows from the power supply line 8 through the second drive transistor 4 and the gate transistor 5 to charge the data line 7 to power supply voltage VDD.
[0037] During this time, the on resistance of the gate transistor 5 is large compared to the on resistance of the second drive transistor 4 , and so the gate potential of the first drive transistor 2 is maintained to the High side by resistance division Data is therefore not corrupted by read out. When the gate terminal of the first drive transistor 2 is being held Low, the data line 7 is pre-charged to Low to read select the gate line 6 , but because the data line 7 is also Low current does not flow and there is no change to the Low potential to which the data line 7 has been pre-charged. In this way, after a fixed time has elapsed from read select, it is possible read out data being held in the static memory by taking in the data line 7 potential.
[0038] FIG. 2 shows a defect detection circuit for detection of defects introduced into an active matrix type organic EL display. Pixels 10 with the above-described readable and writable static memory are arranged in a matrix form to make a display array (display region) 11 . Data lines 7 arranged in the column direction of this display region are connected to a data bus 15 in order from left to right, for example, by a column shift register 13 and bus switches 12 . Also, gate lines 6 arranged in the row direction are sequentially selected from top to bottom, for example by a row shift register 14 , and data supplied to the data bus 15 is written to the pixels 10 .
[0039] In FIG. 2 RGB data buses are shown, and RGB data is input at one time and supplied the corresponding data lines 7 . At this time, the row shift register 14 sequentially selects gate lines 6 one at a time, and so while an nth line is write selected bus switches 12 the same in number as the number of pixel for one line are sequentially turned on from left to right by the column shift register 13 to connect the data bus 15 to the data lines 7 . As a result, RGB data for the n th line supplied to the data bus 15 is written to each pixel 10 . Conversely, if the line is read selected, data for one line that has been read once from a pixel 10 is held on the data line 7 , and data read onto the data line 7 is read out from the data bus 15 by the bus switches 12 sequentially connecting the data lines 7 and the data bus 15 .
[0040] Signals input from outside to the column shift register 13 , row shift register 14 and data bus 15 , or signals output to the outside, are transferred by way of the IO pads 16 . Specifically, control signals generated from external signal generators etc. to the column shift register 13 and row shift register 14 , and power supply voltages, are respectively input from the IO pads 16 - 1 and 16 - 3 . Access to the data bus 15 for inputting RGB data from outside and output data read from the pixels 10 is performed via the IO pads 16 - 2 .
[0041] When performing final defect detection after forming the organic EL elements on the TFT substrate, it is necessary to illuminate all pixels to detect whether or not there are defective pixels, but in the case of pixels with no static memory it is normally necessary to illuminate all pixels by writing image data at 60 Hz. If the resolution of the panel is high or the size is large, there is a need for low impedance outputs and high speed data transfer. For this reason, it is necessary to install a driver IC and perform lighting tests by connecting IO pads of the driver IC to the 10 pads 16 - 4 . However, even supposing that defect inspection can be performed with a driver IC installed, in the event that panel defects exist to an unacceptable level, and they will not be corrected the installed driver IC can not be reused, increasing inspection costs.
[0042] On the other hand, with this embodiment a static memory is incorporated into each pixel 10 . This indicates that if data is written all at once, that data is maintained and it is not necessary to periodically write data. If this function is used, then since there is no need for refresh at the 60 Hz normally required for performing display, it is possible to lower the data transfer speed from outside. Therefore, the use of high performance transistors such as low temperature polysilicon TFTs makes it possible to write data to all pixels through operation of the column shift register 13 , row shift register 14 and bus switches 12 even if the display array 11 is large or high resolution, and perform appropriate display with no flicker. Specifically, since it is not necessary to operate the column shift register 13 , row shift register 14 and bus switches 12 at high speed, their circuit structures can be simplified, and incorporation onto a TFT substrate is made easier.
[0043] For example, if writing for pixels is done with one pixel per RGB respectively, even with a low temperature polysilicon TFT having an operable period of 1 μs, it is possible to write data to all pixels in about two seconds even with the resolution of full high-vision (1920×1080). This is sufficiently fast for inspection. If it were necessary to refresh this data at 60 Hz, data transfer would need to be carried out, per single RGB pixel, at 60×1920×1080=124 MHz (8 ns), which is extremely difficult with low temperature polysilicon TFTs. Even if this is possible, the bus width would be increased, and a greater number of circuits would be used, making it more likely that shorts will arise in the bus wiring adopted to detect these as well as circuit defects, and pixel defect detection is complicated. Specifically, using pixels 10 adopting a static memory suppresses defects in peripheral circuits for pixel defect detection, and also does away with the need for provision of a driver IC, making it possible to minimize inspection cost.
[0044] The static memory of the pixel 10 is also capable of reading data. If this function is utilized, then after writing data to all pixels once it is possible to verify written data by reading data one pixel at a time. This aspect will be described in more detail in the following using FIG. 1 .
[0045] If a defect occurs in the first organic EL element 1 and the cathode electrode 9 and the anode of the first organic element 1 are short circuited, the gate terminal of the second drive transistor 4 is always Low, and so read data will always be High. At the time of verification, Low (white data) is written, and High (black data) is read out, which indictes that verify errors are obvious. If verification is performed by writing white data to all pixels and reading white data from all pixels, and then verifying by writing black data to all pixels and reading out black data, it is possible to determine whether or not the black and white operation of all pixels is appropriate. Alternatively, it is also possible to carry out verification using a verification pattern such as a checkered pattern, vertical stripe pattern or horizontal stripe pattern. Defects that have been detected using this type of verification are not only those relating to the organic EL elements, but also include open circuit faults in the TFTs and between wiring, but regardless of the type of fault, if the location of all defective pixels is specified in this way it is possible to generate a defect map such as is shown in FIG. 3 .
[0046] FIG. 3 shows one example of defect maps for horizontal line defect, vertical line defect and pixel defect. Using white as a normal pixel and black as a defective pixel, these maps are created corresponding to positions of pixels 10 in a display array 11 so as to make it easy to understand verify errors detected as described previously. From this defect map, the case of pixels in a continuous horizontal line can be considered an open circuit gate line 6 , and the case of pixels in a continuous vertical line can be considered an open circuit data line 7 , and if there are pixel defects it can be considered that an individual organic EL element or TFT is defective, and classification of defects by determining data read out by verification becomes possible as well as looking at the display.
[0047] At the time of verification, the organic EL display is lit up, so it is possible to tell just by looking at the display, but if the defect analysis system as shown in FIG. 4 is constructed it is possible to perform defect detection for a large scale panel automatically and more rapidly.
[0048] The defect analysis system of FIG. 4 includes a prober for assigning control signals, data and power supply through probe terminals to IO pads 16 of an organic EL panel 17 having a verify function, and a single personal computer (PC). Control signals, data and power supply are supplied through probe terminals to the IO pads 16 of the organic EL panel 17 to carry out the previously described verification, and detect pixel defects of all pixels. Verify error data is sent from the proper to the PC, a defect map as shown in FIG. 3 is created by PC software, and the number of defective pixels is displayed on a monitor together with defect characteristics. In the event that defects are within admissible conditions, the display panel 17 is transferred to the next manufacturing state, but if there is deviation from the admissible conditions confirmation is carried out by an operator checking defect content against actual display and operation transfers to details specification and solution of the problem. All of this panel defect information can be made into a database, making it possible to keep track of when what defects arose in what panel process and at what time, and easily understand yield improvement conditions.
[0049] The automated defect detection results are to classify panels into those that have room for improvement and those that do not, and those with room for improvement are subjected to the improvement strategy shown in FIG. 5 . FIG. 5 shows an example of a redundant configuration for a display array 11 . Normally, the number of pixels of an effective display region 18 is a number defined by specifications, for example, with full high vision the effective display region is made up of 1920×1080 pixels, but with the example shown in FIG. 5 there are, for example, a further 100 pixels at the left and right and 50 pixels at the top and bottom to give a structure with 2120×1180 pixels. The shaded area of the display array 11 is a standard redundancy region, and in the case where it has been ascertained through the previously described verification that there are prominent defective pixels at a lower right end of the standard effective pixel region shown in white (position denoted by x), it is possible to prevent the organic EL panel 17 becoming defective by moving the effective display region 18 to the dotted line region. Since it is possible to search for regions with no defects using automatic image defect detection, it is possible to find an appropriate region with permissible defects, and reset the effective display region.
[0050] In the case where it has been determined that there are also defective pixels that cannot be permitted in the destination effective display region 18 , it is undesirable to reset the effective display region as described previously. In this case, it is better to be able to dynamically set the effective display region 18 so that it is shifted slightly after a specified time has elapsed without the effective display region 18 being fixed. In the event that an effective display region 18 is set in a standard effective display region of the white section in FIG. 5 in such a time frame, the pixel defects can be seen to the bottom right of the screen, but at the next point in time the effective display region is moved to the dotted line region and so despite the fact that defects in the dotted line region affect display, there is no effect due to the lower right defects. Since defects cannot be seen at a fixed position, it is possible to anticipate the effect that they will not stand out. Further, since the effective display region is moved, it is possible to expect the effect of avoiding screen burn in.
[0051] Making it possible to reset a more flexible effective display region has the effect of avoiding defect display and avoiding screen burn in, and it is desirable to secure a larger redundant display region. However, since the redundant display region is viewed as a frame at the time of use, and if it is large visual quality is not very good, it would be better to keep the redundant display region to about 10% or less of a general panel size.
[0052] In the case where the location of defects is mainly in the center of the display array 11 , it will be difficult to avoid defects using only the method shown in FIG. 5 , but it is possible to make the defects less noticeable by adopting the pixel structure shown in FIG. 6 .
[0053] FIG. 6 shows an example of a plurality of sub pixels, in this case one unit pixel 19 adopting 6 bits (pixels for either of RGB), being formed in a pixel 10 . The ratio of emission intensity of each of the sub pixels 10 - 0 to 10 - 5 is respectively set at 1:2:4:8:16:32, and in FIG. 6 this is realized by varying the light emission surface area of the first organic EL element 1 . However, even if the light emission surface area is varied, it is not strictly necessary to increase by a power of two each time. Specifically, if an application such as a television is assumed, average brightness is about 20%-30% of peak brightness, and pixels are lit up more frequently, which indicates that considering degradation it is advisable to make the light emission surface area of pixels having the above-described emission intensity ratio of 16/63 larger, and considering temperature, to control degradation by making light emission surface area for emission intensity ratio 32/63, that is more prone to be affected, to be even larger. In this case, since the light emission strength is large compared to an assumed ratio, desired light emission strength is realized by controlling light emission period.
[0054] Here, it is possible to realize ratios of emission intensity for the sub-pixels 10 - 0 to 10 - 5 without changing the light emission surface area. In FIG. 11 , a fixed current drive transistor 24 is inserted in series between the first drive transistor 2 and the first organic EL element 1 . Specifically, the fixed current drive transistor 24 has its gate terminal connected to a current control line 25 , and by controlling a potential supplied to this current control line 25 it is possible to vary the emission intensity of the first organic EL element 1 . Thus, by varying the potentials of current control lines 25 respectively connected at each of the sub-pixels, it is possible to vary the emission intensity of each sub-pixel. With the pixel 10 of FIG. 11 when the current control line 25 is made Low the fixed current drive transistor 24 is normally on and operates, and if memory data read and write can be carried out similar automatic defect detection can be carried out.
[0055] In the case of 6 bits, six current control lines 25 are connected to gate terminals of fixed current drive transistors 24 provided in respective sub-pixels, and it is possible to supply six different potentials (V 25 - 0 to V 25 - 5 ) are supplied to give current ratios (10:11:12:13:14:15=1:2:4:8:16:32) such that emission intensity ratios are as described above, as shown in FIG. 12 . If the pixel of FIG. 11 is used, then since it is possible to set the emission intensity with the current value of the first drive transistor 2 , it is not necessary to vary emission surface area and current setting can be carried out arbitrarily which shows control is simple.
[0056] Incidentally, current will be concentrated at the first organic EL element 1 of sub-pixel 10 - 5 , which is the MSB, and that sub-pixel will deteriorate quickly. However, it is possible to resolve this type of problem by exchanging the MSB sub-frame pixels in frame units or a specified period with another sub-pixel, and to switch the potential V 25 - 5 of the current control line 25 - 5 with the potential V 25 - i of any of the remaining current control lines 25 - i. In particular, in the case of surface area gradation, construction is difficult because emission surface area of the LSB sub-pixel is extremely small, being 1/32 compared to that of the MSB. It is therefore preferable to have the pixel of FIG. 11 only for the LSB sub-pixel, and set the emission intensity low. As a result, the number of current control lines required is also reduced.
[0057] If a plurality of sub-pixels are adopted inside a unit pixel as in FIG. 6 , then even if defects arise in the organic EL element of one of these sub-pixels the defect does not appear in the one unit pixel as long as operation of the other sub-pixels is normal. In the case of a unit pixel being made up of only one pixel, then since a single defect constitutes a defect of the unit pixel the risk of defective pixels is high, but if a plurality of sub-pixels are adopted it can be expected that the risk will be dispersed. In the case of surface area gradation, in particular, a defect of sub-pixel 10 - 5 , which is the MSB, has a significant effect on the emission intensity of the unit pixel. For this reason, handling of whether or not this MSB sub-pixel has a defect is given precedence. After inspection of all pixels for defects using the previously described automatic defect detection, if a defect is detected and that defect is toward the center, it is evaluated whether or not the defect is for the MSB sub-pixel. If it is not an MSB sub-pixel defect, the permissible amount of defects for the unit pixel is set low, and defect evaluation is kept low. This is because if the dynamic effective display region setting as in FIG. 5 is adopted, then the location of the defect is relatively moved, which indicates that if at least the MSN sub-pixel is operating normally it can be determined that a defect is unlikely to be prominent. However, if the defect is in the MSB sub-pixel, defect determination is performed according to the defect state of any of the other sub-pixels. If other sub-pixels are operating normally and it is possible, using the dynamic effective display region setting of FIG. 5 to determine that the defect will not be prominent, then a good product is determined, and in the case where there are a lot of defects of surrounding MSB sub-pixels, it is likely that the product will be determined to be defective.
[0058] Using the sub-pixel shown in FIG. 11 , with six sub-pixels having completely the same emission surface area, in the case of controlling gradation by controlling supplied current it is possible to switch the MSB sub-pixel, and it is not fixed, which shows that image defects are unlikely to be prominent. In this manner, if a unit pixel is formed using a plurality of sub-pixels, a defect does not always result directly in a defective unit pixel and so it is possible to improve yield.
[0059] Incidentally, it is better for the number of sub-pixels that that can be adopted to be high, but three bits or four bits is also effective. However, if a lot of sub-pixels are adopted in the unit pixel as in FIG. 6 , the number of pixels is increased which required verification time, and so it is preferable to perform defect determination by preferentially performing automatic defect detection from the MSB sub-pixels, to shorten the verify time.
[0060] Description has been given above for defect detection carried out before shipping, but in the following a description will be given of defect detection after shipping.
[0061] Since organic EL are semiconductors using organic material, it generally has low reliability compared to semiconductors formed from inorganic material such as low temperature polysilicon TFTs. Specifically, it is normally necessary to guarantee the pre-shipping reliability level even after shipping has taken place, but there is concern about lowered reliability dependent upon usage conditions. For example, in the case of organic EL, the elements become high resistance with degradation, making it difficult for current to flow, and there is a possibility that it will become difficult for static memory incorporated into the pixels 10 to operate normally. Therefore, it is preferable to carry out defect detection after shipping also using the read function of the pixels 10 , and in this way it is possible to guarantee that the pixel will operate normally.
[0062] As shown in FIG. 7 , at the time of shipping the product is shipped with the organic EL panel 17 having IO pads of a data driver 20 connected to IO pads 16 - 4 . However, since there is a possibility of connecting to the data bus 15 to the data lines 7 via other bus switches 12 , at the point in time where the data driver IC 20 is connected, the column shift register 13 is controlled to transmit an off signal to all of the bus switches 12 . For example, it is possible in the column shift register 13 to fix the control signal supplied from the IO pad 16 - 1 by pulling up or pulling down with a resistance element.
[0063] Defect detection before shipping also takes place after connecting the data driver 20 , but even if a defect is detected here it is a defect due to connection of the data driver IC 20 and so improvement is simple. There are also situations where a gate driver IC is connected instead of the row shift register 14 , but in FIG. 7 the row shift register 14 is used as a gate driver.
[0064] An organic EL panel 17 that has been shipped with the data driver IC 20 connected has data driver control signals and image data supplied from a control circuit 21 to the data driver IC 20 , and gate driver control signals are also supplied to a gate driver (row shift register 14 ) to normally operate as a display. Defect information detected before shipping is information corresponding to individual organic EL panels 17 shipped with this information prestored in a defect information memory 22 formed from non-volatile memory such as flash memory. Here, positions of defective pixels are listed in the defect information, and is, for example, a small amount of data for a few tens of pixels.
[0065] In this embodiment, in part of a non-usage time of the display, automatic defect detection using the above-described verification is carried out by the data driver IC 20 . Differing from automatic defect detection before shipping, this is carried out at high speed because reading and writing of data to and from the pixels 10 by the data driver IC 20 is carried out in line units. Also, the control circuit 21 checks that defects have not increased on the basis of defect information of the defect information memory 22 . If the defect locations increase, the defect information memory 22 is updated, and as shown in FIG. 5 the effective display region is reset to an appropriate position. If the effective display region is updated dynamically, desired regions as set regions are limited on the basis of the defect information. By updating the defect information in this manner, it is possible to keep the effect on display to a minimum, even if the defective pixels increase. The control circuit 21 and the defect information memory 22 can be built in to the data driver IC 20 .
[0066] Further, by using the structure of FIG. 8 , it is possible to avoid burn in that arises after shipping, which is of the greatest concern in organic EL displays. Burn in can be regarded as some late developing defects of the previously mentioned pixels, and can be reduced by incorporating the comparator 23 as shown in FIG. 8 .
[0067] FIG. 9 shows an example of detecting degradation of a pixel of an n th row m th column using a comparator 23 and an x th line (reference line 6 - x ) constituting a reference provided outside the display section. The same pixels 10 as the display section are provided on the reference line 6 - x. Input output terminals of the data driver IC 20 are connected to each data line 7 , and one comparator 23 is connected. The comparator 23 includes a first switch SW 1 , an inverter INV, a retention capacitor CAP, a 1-bit memory MEM and a second switch SW 2 . The data line 7 is connected to the input of the inverter INV via the retention capacitor CAP. The input and output of the inverter INV are connected using the first switch SW 1 , with the output being connected to the 1-bit memory MEM. The second switch SW 2 controls whether or not output of the 1-bit memory MEM is output to the data line 7 .
[0068] Operation of the comparator 23 will be described using FIG. 9 and FIG. 10 . An example of the data line 7 - m of the m th column is shown in FIG. 9 , but the other data lines 7 also operate in the same way, and are controlled in line units. The pixel circuit is the circuit shown in FIG. 1 .
[0069] First of all, the data line 7 is pre-charged with a potential Vp that will turn the first drive transistor 2 on. At the same time as the first switch SW 1 is turned on, if the x th line is selected then the first drive transistor 2 of the x th line is turned on and the second drive transistor 4 is turned off, and as a result charge that has been pre-charged to the data line 7 is discharged from the second organic EL element 3 during the period tdc that the x th line is selected. The data line 7 is gradually lowered from Vp as discharge progresses, then at the same time as the first switch SW 1 is turned off the x th line is deselected to stop discharge of the data line 7 . The potential Vx of this data line 7 is sampled to the retention capacitor CAP when the first switch SW 1 is opened. Next, after the data line 7 has been pre-charged once more to Vp, if the n th line is selected and discharged in the same period tdc to deselect the n th line the potential of the data line 7 becomes Vn. If the degree of deterioration is different for the second organic EL element 3 of the x th line and the second organic EL element 3 of the n th line, discharge characteristics will also differ due to being made high resistance, and the respective potentials Vx and Vn after discharge will be different. This difference is amplified by the inverter INC, and the result is stored in the 1-bit memory MEM.
[0070] The inverter INV operates as a comparator, as described in the following. While the first switch SW 1 is closed, if the data line 7 is at potential Vx and the first switch is off, the potential Vx acts as a threshold value for the inverter INV. This is because it is equivalent to setting so that if the first switch SW 1 is on, the input of the inverter INV becomes a point between High and Low (a threshold value or reference value), and so that the input of the inverter INV becomes the threshold value when the data line 7 becomes Vx on the retention capacitor CAP. Accordingly, while the first switch SW 1 is off, if the potential of the data line 7 is made Vx or less the inverter INV inverts. If this operation is utilized, it is possible to perform a comparison between Vx and Vn. Specifically, a reference voltage for the comparator 23 is first set to the potential Vx of the xth line, then the potential Vn is compared with the reference potential Vx and the result stored in the 1-bit memory MEM.
[0071] Data stored in the 1-bit memory MEM is reflected onto the data line 7 by switching the second switch SW 2 on, and results are read from the input terminal of the data driver IC 20 . This series of operations is carried out for all data lines 7 , which indicates processing is performed in line units and it is possible to read out differences in degradation of the x th line and the n th line at high speed.
[0072] Similarly for the case of the n+1 th line also, first the reference voltage for the x th line is set in the comparator 23 , and the potential Vn+1 of the n+1 th line is compared. Comparison data is stored in the 1-bit memory MEM, and read into the data drive IC 20 . If this is repeated for all lines, it is possible to read out difference in degradation of the second organic EL element 3 when the x th line of all pixels is made a reference, and it is possible to confirm difference in degradation for each pixel.
[0073] With FIG. 9 the voltage values Vx and Vn of the data line 7 have been compared using the comparator 23 , but is also possible measure to current values Ix, In when Vp is applied, using a current measurement circuit or the like (not shown), and to compare these current values.
[0074] The second organic EL element 3 operates in a complementary fashion so as to not emit light while the first organic element 1 is emitting light, and conversely to emit light when the first organic EL element 1 is not emitting light, and so a reverse characteristic for the degradation of the first organic EL element 1 is reflected at the second organic EL element 3 . Specifically, the fact that the second organic EL element 3 is degraded shows that the first organic EL element 1 is not degraded, and as long as the second organic EL element 3 is not degraded, degradation of the first organic EL element 1 advances.
[0075] In the case where the difference in degradation has been confirmed, degradation equalization processing, that will be described next, is carried out in a display non-use period. A pixel having less degradation than the reference line is illuminated for part of the non-use period, to forcibly cause degradation. At this time, since the degradation equalization processing will not be noticeable if the pixel is not lit up very brightly, it is preferable to perform gentle degradation by lowering the power supply voltage VDD further, etc. After a fixed time has elapsed, degradation comparison is again carried out for every pixel with the reference line, and subject to confirmation that the number of pixels that are brighter than the reference line has decreased, it is determined whether or not to carry out degradation equalization again. In the event that there are still a lot of pixels with slight degradation, the equalization processing is performed again, followed by degradation comparison. Once the pixels having slight degradation satisfy a specified condition, the equalization processing is finished, and a state where burn in has been equalized is maintained.
[0076] Here, the reference line preferably causes operation so that during a usage period of the display all pixels of one line are lit at the same brightness to give the same degradation, and it is also possible to shorten the discharge period tdc, to perform control so as to cause apparent degradation and carry out degradation comparison. It is also possible to form the comparator 23 on the same substrate as the pixels, and it is also possible to adopt the comparator 23 inside the data driver IC 20 .
[0077] In this way, it is possible to further improve reliability of display after shipping by verifying pixels periodically after shipping, and monitoring degradation states.
[0078] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
[0000]
1 organic EL element
2 first drive transistor
3 organic EL element
4 second drive transistor
5 gate transistor
6 gate line
7 data line
8 power supply line
10 pixel
11 display array
12 bus switches
13 shift register
14 row shift register
15 data bus
16 IO pads
17 organic EL panel
18 display region
19 unit pixel
20 data driver IC
21 control circuit
22 defect information memory
23 comparator
24 current drive transistor
25 current control line | A method of detecting a defect in a display panel, includes providing a display panel comprising a plurality of pixels arranged in a matrix form, wherein each pixel comprises a static memory and emits light according to data stored in the static memory; writing data to the static memory of each pixel; reading the data stored in the static memory of each pixel; and comparing the data written and read for each pixel to produce a respective comparison result indicating presence of a defect. | 6 |
FIELD OF THE INVENTION
This invention relates to golf balls, particularly to golf balls having improved dimple patterns. More particularly, the invention relates to methods of arranging dimples on a golf ball by generating irregular domains based on polyhedrons, packing the irregular domains with dimples, and tessellating the domains onto the surface of the golf ball.
BACKGROUND OF THE INVENTION
Historically, dimple patterns for golf balls have had a variety of geometric shapes, patterns, and configurations. Primarily, patterns are laid out in order to provide desired performance characteristics based on the particular ball construction, material attributes, and player characteristics influencing the ball's initial launch angle and spin conditions. Therefore, pattern development is a secondary design step that is used to achieve the appropriate aerodynamic behavior, thereby tailoring ball flight characteristics and performance.
Aerodynamic forces generated by a ball in flight are a result of its velocity and spin. These forces can be represented by a lift force and a drag force. Lift force is perpendicular to the direction of flight and is a result of air velocity differences above and below the rotating ball. This phenomenon is attributed to Magnus, who described it in 1853 after studying the aerodynamic forces on spinning spheres and cylinders, and is described by Bernoulli's Equation, a simplification of the first law of thermodynamics. Bernoulli's equation relates pressure and velocity where pressure is inversely proportional to the square of velocity. The velocity differential, due to faster moving air on top and slower moving air on the bottom, results in lower air pressure on top and an upward directed force on the ball.
Drag is opposite in sense to the direction of flight and orthogonal to lift. The drag force on a ball is attributed to parasitic drag forces, which consist of pressure drag and viscous or skin friction drag. A sphere is a bluff body, which is an inefficient aerodynamic shape. As a result, the accelerating flow field around the ball causes a large pressure differential with high-pressure forward and low-pressure behind the ball. The low pressure area behind the ball is also known as the wake. In order to minimize pressure drag, dimples provide a means to energize the flow field and delay the separation of flow, or reduce the wake region behind the ball. Skin friction is a viscous effect residing close to the surface of the ball within the boundary layer.
The industry has seen many efforts to maximize the aerodynamics of golf balls, through dimple disturbance and other methods, though they are closely controlled by golf's national governing body, the United States Golf Association (U.S.G.A.). One U.S.G.A. requirement is that golf balls have aerodynamic symmetry. Aerodynamic symmetry allows the ball to fly with a very small amount of variation no matter how the golf ball is placed on the tee or ground. Preferably, dimples cover the maximum surface area of the golf ball without detrimentally affecting the aerodynamic symmetry of the golf ball.
In attempts to improve aerodynamic symmetry, many dimple patterns are based on geometric shapes. These may include circles, hexagons, triangles, and the like. Other dimple patterns are based in general on the five Platonic Solids including icosahedron, dodecahedron, octahedron, cube, or tetrahedron. Yet other dimple patterns are based on the thirteen Archimedian Solids, such as the small icosidodecahedron, rhomicosidodecahedron, small rhombicuboctahedron, snub cube, snub dodecahedron, or truncated icosahedron. Furthermore, other dimple patterns are based on hexagonal dipyramids. Because the number of symmetric solid plane systems is limited, it is difficult to devise new symmetric patterns. Moreover, dimple patterns based some of these geometric shapes result in less than optimal surface coverage and other disadvantageous dimple arrangements. Therefore, dimple properties such as number, shape, size, and arrangement are often manipulated in an attempt to generate a golf ball that has better aerodynamic properties.
U.S. Pat. No. 5,562,552 to Thurman discloses a golf ball with an icosahedral dimple pattern, wherein each triangular face of the icosahedron is split by a three straight lines which each bisect a corner of the face to form 3 triangular faces for each icosahedral face, wherein the dimples are arranged consistently on the icosahedral faces.
U.S. Pat. No. 5,046,742 to Mackey discloses a golf ball with dimples packed into a 32-sided polyhedron composed of hexagons and pentagons, wherein the dimple packing is the same in each hexagon and in each pentagon.
U.S. Pat. No. 4,998,733 to Lee discloses a golf ball formed of ten “spherical” hexagons each split into six equilateral triangles, wherein each triangle is split by a bisecting line extending between a vertex of the triangle and the midpoint of the side opposite the vertex, and the bisecting lines are oriented to achieve improved symmetry.
U.S. Pat. No. 6,682,442 to Winfield discloses the use of polygons as packing elements for dimples to introduce predictable variance into the dimple pattern. The polygons extend from the poles of the ball to a parting line. Any space not filled with dimples from the polygons is filled with other dimples.
A continuing need exists for a dimple pattern whose dimple arrangement results in a maximized surface coverage and desirable aerodynamic characteristics, including improved symmetry.
SUMMARY OF THE INVENTION
The present invention provides a method for arranging dimples on a golf ball surface that significantly improves aerodynamic symmetry and minimizes parting line visibility by arranging the dimples in a pattern derived from at least one irregular domain generated from a regular or non-regular polyhedron. The method includes choosing control points of a polyhedron, generating an irregular domain based on those control points, packing the irregular domain with dimples, and tessellating the irregular domain to cover the surface of the golf ball. The control points include the center of a polyhedral face, a vertex of the polyhedron, a midpoint or other point on an edge of the polyhedron and others. The method ensures that the symmetry of the underlying polyhedron is preserved while minimizing great circles due to parting lines from the molding process.
The present invention provides methods for generating an irregular domain based on two or more control points. These methods include connecting the control points with a non-linear sketch line, patterning the sketch line in a first manner to create a first irregular domain, and optionally patterning the sketch line in a second manner to create a second irregular domain.
The present invention also provides methods for generating one or more irregular domains based on each set of control points. The center to vertex method, the center to midpoint method, the vertex to midpoint method, the center to edge method, and the midpoint to center to vertex method each provide a single irregular domain that can be tessellated to cover a golf ball. The center to center method, the midpoint to midpoint method, and the vertex to vertex method each provide two irregular domains that can be tessellated to cover a golf ball. In each case, the irregular domains cover the surface of the golf ball in a uniform pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings which form a part of the specification and are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views:
FIG. 1A illustrates a golf ball having dimples arranged by a method of the present invention; FIG. 1B illustrates a polyhedron face; FIG. 1C illustrates an element of the present invention in the polyhedron face of FIG. 1B ; FIG. 1D illustrates a domain formed by a methods of the present invention packed with dimples and formed from two elements of FIG. 1C ;
FIG. 2 illustrates a single face of a polyhedron having control points thereon;
FIG. 3A illustrates a polyhedron face; FIG. 3B illustrates an element of the present invention packed with dimples; FIG. 3C illustrates a domain of the present invention packed with dimples formed from elements of FIG. 3B ; FIG. 3D illustrates a golf ball formed by a method of the present invention formed of the domain of FIG. 3C ;
FIG. 4A illustrates two polyhedron faces; FIG. 4B illustrates a first domain of the present invention in the two polyhedron faces of FIG. 4A ; FIG. 4C illustrates a first domain and a second domain of the present invention in three polyhedron faces; FIG. 4D illustrates a golf ball formed by a method of the present invention formed of the domains of FIG. 4C ;
FIG. 5A illustrates a polyhedron face; FIG. 5B illustrates a first domain of the present invention in a polyhedron face; FIG. 5C illustrates a first domain and a second domain of the present invention in three polyhedron faces; FIG. 5D illustrates a golf ball formed using a method of the present invention formed of the domains of FIG. 5C ;
FIG. 6A illustrates a polyhedron face; FIG. 6B illustrates a portion of a domain of the present invention in the polyhedron face of FIG. 6A ; FIG. 6C illustrates a domain formed by the methods of the present invention; FIG. 6D illustrates a golf ball formed using the methods of the present invention formed of domains of FIG. 6C ;
FIG. 7A illustrates a polyhedron face; FIG. 7B illustrates a domain of the present invention in the polyhedron face of FIG. 7A ; FIG. 7C illustrates a golf ball formed by a method of the present invention;
FIG. 8A illustrates a first element of the present invention in a polyhedron face; FIG. 8B illustrates a first and a second element of the present invention in the polyhedron face of FIG. 8A ; FIG. 8C illustrates two domains of the present invention composed of first and second elements of FIG. 8B ; FIG. 8D illustrates a single domain of the present invention based on the two domains of FIG. 8C ; FIG. 8E illustrates a golf ball formed using a method of the present invention formed of the domains of FIG. 8D ;
FIG. 9A illustrates a polyhedron face; FIG. 9B illustrates an element of the present invention in the polyhedron face of FIG. 9A ; FIG. 9C illustrates two elements of FIG. 9B combining to form a domain of the present invention;
FIG. 9D illustrates a domain formed by the methods of the present invention based on the elements of FIG. 9C ; FIG. 9E illustrates a golf ball formed using a method of the present invention formed of domains of FIG. 9D ;
FIG. 10A illustrates a face of a rhombic dodecahedron; FIG. 10B illustrates a segment of the present invention in the face of FIG. 10A ; FIG. 10C illustrates the segment of FIG. 10B and copies thereof forming a domain of the present invention; FIG. 10D illustrates a domain formed by a method of the present invention based on the segments of FIG. 10C ; and FIG. 10E illustrates a golf ball formed by a method of the present invention formed of domains of FIG. 10D .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one embodiment, illustrated in FIG. 1A , the present invention comprises a golf ball 10 comprising dimples 12 . Dimples 12 are arranged by packing irregular domains 14 with dimples, as seen best in FIG. 1D . Irregular domains 14 are created in such a way that, when tessellated on the surface of golf ball 10 , they impart greater orders of symmetry to the surface than prior art balls. The irregular shape of domains 14 additionally minimize the appearance and effect of the golf ball parting line from the molding process, and allows greater flexibility in arranging dimples than would be available with regularly shaped domains.
The irregular domains can be defined through the use of any one of the exemplary methods described herein. Each method produces one or more unique domains based on circumscribing a sphere with the vertices of a regular polyhedron. The vertices of the circumscribed sphere based on the vertices of the corresponding polyhedron with origin (0,0,0) are defined below in Table 1.
TABLE 1
Vertices of Circumscribed Sphere based on Corresponding
Polyhedron Vertices
Type of
Polyhedron
Vertices
Tetrahedron
(+1, +1, +1); (−1, −1, +1); (−1, +1, −1); (+1, −1, −1)
Cube
(±1, ±1, ±1)
Octahedron
(±1, 0, 0); (0, ±1, 0); (0, 0, ±1)
Dodecahedron
(±1, ±1, ±1); (0, ±1/φ, ±φ); (±1/φ, ±φ, 0); (±φ, 0, ±1/φ)*
Icosahedron
(0, ±1, ±φ); (±1, ±φ, 0); (±φ, 0, ±1)*
*φ = (1 + {square root over (5)})/2
Each method has a unique set of rules which are followed for the domain to be symmetrically patterned on the surface of the golf ball. Each method is defined by the combination of at least two control points. These control points, which are taken from one or more faces of a regular or non-regular polyhedron, consist of at least three different types: the center C of a polyhedron face; a vertex V of a face of a regular polyhedron; and the midpoint M of an edge of a face of the polyhedron. FIG. 2 shows an exemplary face 16 of a polyhedron (a regular dodecahedron in this case) and one of each a center C, a midpoint M, a vertex V, and an edge E on face 16 . The two control points C, M, or V may be of the same or different types. Accordingly, six types of methods for use with regular polyhedrons are defined as follows:
1. Center to midpoint (C→M);
2. Center to center (C→C);
3. Center to vertex (C→V);
4. Midpoint to midpoint (M→M);
5. Midpoint to Vertex (M→V); and
6. Vertex to Vertex (V→V).
While each method differs in its particulars, they all follow the same basic scheme. First, a non-linear sketch line is drawn connecting the two control points. This sketch line may have any shape, including, but not limited, to an arc, a spline, two or more straight or arcuate lines or curves, or a combination thereof. Second, the sketch line is patterned in a method specific manner to create a domain, as discussed below. Third, when necessary, the sketch line is patterned in a second fashion to create a second domain.
While the basic scheme is consistent for each of the six methods, each method preferably follows different steps in order to generate the domains from a sketch line between the two control points, as described below with reference to each of the methods individually.
The Center to Vertex Method
Referring again to FIGS. 1A-1D , the center to vertex method yields one domain that tessellates to cover the surface of golf ball 10 . The domain is defined as follows:
1. A regular polyhedron is chosen ( FIGS. 1A-1D use an icosahedron); 2. A single face 16 of the regular polyhedron is chosen, as shown in FIG. 1B ; 3. Center C of face 16 , and a first vertex V 1 of face 16 are connected with any non-linear sketch line, hereinafter referred to as a segment 18 ; 4. A copy 20 of segment 18 is rotated about center C, such that copy 20 connects center C with vertex V 2 adjacent to vertex V 1 . The two segments 18 and 20 and the edge E connecting vertices V 1 and V 2 define an element 22 , as shown best in FIG. 1C ; and 5. Element 22 is rotated about midpoint M of edge E to create a domain 14 , as shown best in FIG. 1D .
When domain 14 is tessellated to cover the surface of golf ball 10 , as shown in FIG. 1A , a different number of total domains 14 will result depending on the regular polyhedron chosen as the basis for control points C and V 1 . The number of domains 14 used to cover the surface of golf ball 10 is equal to the number of faces P F of the polyhedron chosen times the number of edges P E per face of the polyhedron divided by 2, as shown below in Table 2.
Domains Resulting from Use of Specific Polyhedra when Using the Center to Vertex Method
Domains Resulting From Use of Specific Polyhedra When
Using the Center to Vertex Method
Type of
Number of
Number of
Number of
Polyhedron
Faces, P F
Edges, P E
Domains 14
Tetrahedron
4
3
6
Cube
6
4
12
Octahedron
8
3
12
Dodecahedron
12
5
30
Icosahedron
20
3
30
The Center to Midpoint Method
Referring to FIGS. 3A-3D , the center to midpoint method yields a single irregular domain that can be tessellated to cover the surface of golf ball 10 . The domain is defined as follows:
1. A regular polyhedron is chosen ( FIGS. 3A-3D use a dodecahedron); 2. A single face 16 of the regular polyhedron is chosen, as shown in FIG. 3A ; 3. Center C of face 16 , and midpoint M 1 of a first edge E 1 of face 16 are connected with a segment 18 ; 4. A copy 20 of segment 18 is rotated about center C, such that copy 20 connects center C with a midpoint M 2 of a second edge E 2 adjacent to first edge E 1 . The two segments 16 and 18 and the portions of edge E 1 and edge E 2 between midpoints M 1 and M 2 define an element 22 ; and 5. Element 22 is patterned about vertex V of face 16 which is contained in element 22 and connects edges E 1 and E 2 to create a domain 14 .
When domain 14 is tessellated around a golf ball 10 to cover the surface of golf ball 10 , as shown in FIG. 3D , a different number of total domains 14 will result depending on the regular polyhedron chosen as the basis for control points C and M 1 . The number of domains 14 used to cover the surface of golf ball 10 is equal to the number of vertices P V of the chosen polyhedron, as shown below in Table 3.
TABLE 3
Domains Resulting From Use of Specific Polyhedra When
Using the Center to Midpoint Method
Number of
Number of
Type of Polyhedron
Vertices, P V
Domains 14
Tetrahedron
4
4
Cube
8
8
Octahedron
6
6
Dodecahedron
20
20
Icosahedron
12
12
The Center to Center Method
Referring to FIGS. 4A-4D , the center to center method yields two domains that can be tessellated to cover the surface of golf ball 10 . The domains are defined as follows:
1. A regular polyhedron is chosen ( FIGS. 4A-4D use a dodecahedron); 2. Two adjacent faces 16 a and 16 b of the regular polyhedron are chosen, as shown in FIG. 4A ; 3. Center C 1 of face 16 a , and center C 2 of face 16 b are connected with a segment 18 ; 4. A copy 20 of segment 18 is rotated 180 degrees about the midpoint M between centers C 1 and C 2 , such that copy 20 also connects center C 1 with center C 2 , as shown in FIG. 4B . The two segments 16 and 18 define a first domain 14 a ; and 5. Segment 18 is rotated equally about vertex V to define a second domain 14 b , as shown in FIG. 4C .
When first domain 14 a and second domain 14 b are tessellated to cover the surface of golf ball 10 , as shown in FIG. 4D , a different number of total domains 14 a and 14 b will result depending on the regular polyhedron chosen as the basis for control points C 1 and C 2 . The number of first and second domains 14 a and 14 b used to cover the surface of golf ball 10 is P F *P E /2 for first domain 14 a and P V for second domain 14 b , as shown below in Table 4.
TABLE 4
Domains Resulting From Use of Specific Polyhedra When
Using the Center to Center Method
Number
Number
Number
Number
Number
of
of First
of
of
of Second
Type of
Vertices,
Domains
Faces,
Edges,
Domains
Polyhedron
P V
14a
P F
P E
14b
Tetrahedron
4
6
4
3
4
Cube
8
12
6
4
8
Octahedron
6
9
8
3
6
Dodecahedron
20
30
12
5
20
Icosahedron
12
18
20
3
12
The Midpoint to Midpoint Method
Referring to FIGS. 5A-5D , the midpoint to midpoint method yields two domains that tessellate to cover the surface of golf ball 10 . The domains are defined as follows:
1. A regular polyhedron is chosen ( FIGS. 5A-5D use a dodecahedron); 2. A single face 16 of the regular polyhedron is chosen, as shown in FIG. 5A ; 3. The midpoint M 1 of a first edge E 1 of face 16 , and the midpoint M 2 of a second edge E 2 adjacent to first edge E 1 are connected with a segment 18 ; 4. Segment 18 is patterned around center C of face 16 to form a first domain 14 a , as shown in FIG. 5B ; 5. Segment 18 , along with the portions of first edge E 1 and second edge E 2 between midpoints M 1 and M 2 , define an element 22 ; and 6. Element 22 is patterned about vertex V which is contained in element 22 and connects edges E 1 and E 2 to create a second domain 14 b , as shown in FIG. 5C .
When first domain 14 a and second domain 14 b are tessellated to cover the surface of golf ball 10 , as shown in FIG. 5D , a different number of total domains 14 a and 14 b will result depending on the regular polyhedron chosen as the basis for control points M 1 and M 2 . The number of first and second domains 14 a and 14 b used to cover the surface of golf ball 10 is P F for first domain 14 a and P V for second domain 14 b , as shown below in Table 5.
TABLE 5
Domains Resulting From Use of Specific Polyhedra When
Using the Center to Center Method
Number of
Number of
Type of
Number of
Number of First
Vertices,
Second
Polyhedron
Faces, P F
Domains 14a
P V
Domains 14b
Tetrahedron
4
4
4
4
Cube
6
6
8
8
Octahedron
8
8
6
6
Dodecahedron
12
12
20
20
Icosahedron
20
20
12
12
The Midpoint to Vertex Method
Referring to FIGS. 6A-6D , the midpoint to vertex method yields one domain that tessellates to cover the surface of golf ball 10 . The domain is defined as follows:
1. A regular polyhedron is chosen ( FIGS. 6A-6D use a dodecahedron); 2. A single face 16 of the regular polyhedron is chosen, as shown in FIG. 6A ; 3. A midpoint M 1 of edge E 1 of face 16 and a vertex V 1 on edge E 1 are connected with a segment 18 ; 4. Copies 20 of segment 18 is patterned about center C of face 16 , one for each midpoint M 2 and vertex V 2 of face 16 , to define a portion of domain 14 , as shown in FIG. 6B ; and 5. Segment 18 and copies 20 are then each rotated 180 degrees about their respective midpoints to complete domain 14 , as shown in FIG. 6C .
When domain 14 is tessellated to cover the surface of golf ball 10 , as shown in FIG. 6D , a different number of total domains 14 will result depending on the regular polyhedron chosen as the basis for control points M 1 and V 1 . The number of domains 14 used to cover the surface of golf ball 10 is P F , as shown in Table 6.
TABLE 6
Domains Resulting From Use of Specific Polyhedra When
Using the Midpoint to Vertex Method
Number of
Number of
Type of Polyhedron
Faces, P F
Domains 14
Tetrahedron
4
4
Cube
6
6
Octahedron
8
8
Dodecahedron
12
12
Icosahedron
20
20
The Vertex to Vertex Method
Referring to FIGS. 7A-7C , the vertex to vertex method yields two domains that tessellate to cover the surface of golf ball 10 . The domains are defined as follows:
1. A regular polyhedron is chosen ( FIGS. 7A-7C use an icosahedron); 2. A single face 16 of the regular polyhedron is chosen, as shown in FIG. 7A ; 3. A first vertex V 1 face 16 , and a second vertex V 2 adjacent to first vertex V 1 are connected with a segment 18 ; 4. Segment 18 is patterned around center C of face 16 to form a first domain 14 a , as shown in FIG. 7B ; 5. Segment 18 , along with edge E 1 between vertices V 1 and V 2 , defines an element 22 ; and 6. Element 22 is rotated around midpoint M 1 of edge E 1 to create a second domain 14 b.
When first domain 14 a and second domain 14 b are tessellated to cover the surface of golf ball 10 , as shown in FIG. 7C , a different number of total domains 14 a and 14 b will result depending on the regular polyhedron chosen as the basis for control points V 1 and V 2 . The number of first and second domains 14 a and 14 b used to cover the surface of golf ball 10 is P F for first domain 14 a and P F *P E /2 for second domain 14 b , as shown below in Table 7.
TABLE 7
Domains Resulting From Use of Specific Polyhedra When
Using the Vertex to Vertex Method
Number of
Number of
Type of
Number of
Number of First
Edges per
Second
Polyhedron
Faces, P F
Domains 14a
Face, P E
Domains 14b
Tetrahedron
4
4
3
6
Cube
6
6
4
12
Octahedron
8
8
3
12
Dodecahedron
12
12
5
30
Icosahedron
20
20
3
30
While the six methods previously described each make use of two control points, it is possible to create irregular domains based on more than two control points. For example, three, or even more, control points may be used. The use of additional control points allows for potentially different shapes for irregular domains. An exemplary method using a midpoint M, a center C and a vertex V as three control points for creating one irregular domain is described below.
The Midpoint to Center to Vertex Method
Referring to FIGS. 8A-8E , the midpoint to center to vertex method yields one domain that tessellates to cover the surface of golf ball 10 . The domain is defined as follows:
1. A regular polyhedron is chosen ( FIGS. 8A-8E use an icosahedron); 2. A single face 16 of the regular polyhedron is chosen, as shown in FIG. 8A ; 3. A midpoint M 1 on edge E 1 of face 16 , Center C of face 16 and a vertex V 1 on edge E 1 are connected with a segment 18 , and segment 18 and the portion of edge E 1 between midpoint M 1 and vertex V 1 define a first element 22 a , as shown in FIG. 8A ; 4. A copy 20 of segment 18 is rotated about center C, such that copy 20 connects center C with a midpoint M 2 on edge E 2 adjacent to edge E 1 , and connects center C with a vertex V 2 at the intersection of edges E 1 and E 2 , and the portion of segment 18 between midpoint M 1 and center C, the portion of copy 20 between vertex V 2 and center C, and the portion of edge E 1 between midpoint M 1 and vertex V 2 define a second element 22 b , as shown in FIG. 8B ; 5. First element 22 a and second element 22 b are rotated about midpoint M 1 of edge E 1 , as seen in FIG. 8C , to define two domains 14 , wherein a single domain 14 is bounded solely by portions of segment 18 and copy 20 and the rotation 18 ′ of segment 18 , as seen in FIG. 8D .
When domain 14 is tessellated to cover the surface of golf ball 10 , as shown in FIG. 8E , a different number of total domains 14 will result depending on the regular polyhedron chosen as the basis for control points M, C, and V. The number of domains 14 used to cover the surface of golf ball 10 is equal to the number of faces P F of the polyhedron chosen times the number of edges P E per face of the polyhedron, as shown below in Table 8.
TABLE 8
Domains Resulting From Use of Specific Polyhedra When
Using the Midpoint to Center to Vertex Method
Type of
Number of
Number of
Number of
Polyhedron
Faces, P F
Edges, P E
Domains 14
Tetrahedron
4
3
12
Cube
6
4
24
Octahedron
8
3
24
Dodecahedron
12
5
60
Icosahedron
20
3
60
While the methods described previously provide a framework for the use of center C, vertex V, and midpoint M as the only control points, other control points are useable. For example, a control point may be any point P on an edge E of the chosen polyhedron face. When this type of control point is used, additional types of domains may be generated, though the mechanism for creating the irregular domain(s) may be different. An exemplary method, using a center C and a point P on an edge, for creating one such irregular domain is described below.
The Center to Edge Method
Referring to FIGS. 9A-9E , the center to edge method yields one domain that tessellates to cover the surface of golf ball 10 . The domain is defined as follows:
1. A regular polyhedron is chosen ( FIGS. 9A-9E use an icosahedron); 2. A single face 16 of the regular polyhedron is chosen, as shown in FIG. 9A ; 3. Center C of face 16 , and a point P 1 on edge E 1 are connected with a segment 18 ; 4. A copy 20 of segment 18 is rotated about center C, such that copy 20 connects center C with a point P 2 on edge E 2 adjacent to edge E 1 , where point P 2 is positioned identically relative to edge E 2 as point P 1 is positioned relative to edge E 1 , such that the two segments 18 and 20 and the portions of edges E 1 and E 2 between points P 1 and P 2 , respectively, and a vertex V, which connects edges E 1 and E 2 , define an element 22 , as shown best in FIG. 9B ; and 5. Element 22 is rotated about midpoint M 1 of edge E 1 or midpoint M 2 of edge E 2 , whichever is located within element 22 , as seen in FIGS. 9B-9C , to create a domain 14 , as seen in FIG. 9D .
When domain 14 is tessellated to cover the surface of golf ball 10 , as shown in FIG. 9E , a different number of total domains 14 will result depending on the regular polyhedron chosen as the basis for control points C and P 1 . The number of domains 14 used to cover the surface of golf ball 10 is equal to the number of faces P F of the polyhedron chosen times the number of edges P E per face of the polyhedron divided by 2, as shown below in Table 9.
TABLE 9
Domains Resulting From Use of Specific Polyhedra When
Using the Center to Edge Method
Type of
Number of
Number of
Number of
Polyhedron
Faces, P F
Edges, P E
Domains 14
Tetrahedron
4
3
6
Cube
6
4
12
Octahedron
8
3
12
Dodecahedron
12
5
30
Icosahedron
20
3
30
Though each of the above described methods has been explained with reference to regular polyhedrons, they may also be used with certain non-regular polyhedrons, such as Archimedean Solids, Catalan Solids, or others. The methods used to derive the irregular domains will generally require some modification in order to account for the non-regular face shapes of the non-regular solids. An exemplary method for use with a Catalan Solid, specifically a rhombic dodecahedron, is described below.
A Vertex to Vertex Method for a Rhombic Dodecahedron
Referring to FIGS. 10A-10E , a vertex to vertex method based on a rhombic dodecahedron yields one domain that tessellates to cover the surface of golf ball 10 . The domain is defined as follows:
1. A single face 16 of the rhombic dodecahedron is chosen, as shown in FIG. 10A ; 2. A first vertex V 1 face 16 , and a second vertex V 2 adjacent to first vertex V 1 are connected with a segment 18 , as shown in FIG. 10B ; 3. A first copy 20 of segment 18 is rotated about vertex V 2 , such that it connects vertex V 2 to vertex V 3 of face 16 , a second copy 24 of segment 18 is rotated about center C, such that it connects vertex V 3 and vertex V 4 of face 16 , and a third copy 26 of segment 18 is rotated about vertex V 1 such that it connects vertex V 1 to vertex V 4 , all as shown in FIG. 10C , to form a domain 14 , as shown in FIG. 10D ;
When domain 14 is tessellated to cover the surface of golf ball 10 , as shown in FIG. 10E , twelve domains will be used to cover the surface of golf ball 10 , one for each face of the rhombic dodecahedron.
After the irregular domain(s) is created using any of the above methods, the domain(s) may be packed with dimples in order to be usable in creating golf ball 10 . There are no limitations on how the dimples are packed. There are likewise no limitations to the dimple shapes or profiles selected to pack the domains. Though the present invention includes substantially circular dimples in one embodiment, dimples or protrusions (brambles) having any desired characteristics and/or properties may be used. For example, in one embodiment the dimples may have a variety of shapes and sizes including different depths and widths. In particular, the dimples may be concave hemispheres, or they may be triangular, square, hexagonal, catenary, polygonal or any other shape known to those skilled in the art. They may also have straight, curved, or sloped edges or sides. To summarize, any type of dimple or protrusion (bramble) known to those skilled in the art may be used with the present invention. The dimples may all fit within each domain, as seen in FIGS. 1A and 1D , or dimples may be shared between one or more domains, as seen in FIGS. 3C-3D , so long as the dimple arrangement on each independent domain remains consistent across all copies of that domain on the surface of a particular golf ball. Alternatively, the tessellation can create a pattern that covers more than about 60%, preferably more than about 70% and preferably more than about 80% of the golf ball surface without using dimples.
In other embodiments, the domains may not be packed with dimples, and the borders of the irregular domains may instead comprise ridges or channels. In golf balls having this type of irregular domain, the one or more domains or sets of domains preferably overlap to increase surface coverage of the channels. Alternatively, the borders of the irregular domains may comprise ridges or channels and the domains are packed with dimples.
When the domain(s) is patterned onto the surface of a golf ball, the arrangement of the domains dictated by their shape and the underlying polyhedron ensures that the resulting golf ball has a high order of symmetry, equaling or exceeding 12. The order of symmetry of a golf ball produced using the method of the current invention will depend on the regular or non-regular polygon on which the irregular domain is based. The order and type of symmetry for golf balls produced based on the five regular polyhedra are listed below in Table 10.
TABLE 10
Symmetry of Golf Ball of the Present Invention as a Function
of Polyhedron
Type of
Symmetrical
Polyhedron
Type of Symmetry
Order
Tetrahedron
Chiral Tetrahedral Symmetry
12
Cube
Chiral Octahedral Symmetry
24
Octahedron
Chiral Octahedral Symmetry
24
Dodecahedron
Chiral Icosahedral Symmetry
60
Icosahedron
Chiral Icosahedral Symmetry
60
These high orders of symmetry have several benefits, including more even dimple distribution, the potential for higher packing efficiency, and improved means to mask the ball parting line. Further, dimple patterns generated in this manner may have improved flight stability and symmetry as a result of the higher degrees of symmetry.
In other embodiments, the irregular domains do not completely cover the surface of the ball, and there are open spaces between domains that may or may not be filled with dimples. This allows dissymmetry to be incorporated into the ball.
While the preferred embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not of limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. For example, while the preferred polyhedral shapes have been provided above, other polyhedral shapes could also be used. Thus the present invention should not be limited by the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | The present invention provides a method for arranging dimples on a golf ball surface that significantly improves aerodynamic symmetry and minimizes parting line visibility by arranging the dimples in a pattern derived from at least one irregular domain generated from a regular or non-regular polyhedron. The method includes choosing control points of a polyhedron, generating an irregular domain based on those control points, packing the irregular domain with dimples, and tessellating the irregular domain to cover the surface of the golf ball. The control points include the center of a polyhedral face, a vertex of the polyhedron, a midpoint or other point on an edge of the polyhedron and others. The method ensures that the symmetry of the underlying polyhedron is preserved while eliminating great circles due to parting lines. | 0 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a technique for preventing peel of a package interface and crack when a surface package type semiconductor package is mounted to a packaging substrate such as a printed circuit board.
[0002] In surface mount package type semiconductor packages such as a small outline package (SOP), a squad flat package (QFP), a plastic leaded chip carrier (PLCC), and the like, the size and thickness of the packages are more and more reduced in order to cope with the increase in the size of a semiconductor chip stored in the package and package strength tends to decrease.
[0003] Therefore, it has become difficult to produce a thin resin molded IC having high reliability.
[0004] Incidentally, mentioned can be made of “IC PACKAGING TECHNIQUE”, published by Kogyo Chosakai K.K., Jan. 15, 1980, pp. 135-156, as a prior art reference describing surface package type semiconductor packages.
[0005] Furthermore, as disclosed in Japanese Patent Laid-Open No. 178877/1986 by Otsuka et al. (Aug. 11, 1986), a proposal has been made to put a desiccant into a magazine or to seal a conveying tray in a bag of a vinyl sheet or the like.
SUMMARY OF THE INVENTION
[0006] When examining packaging reliability and strength of these thin type packages, the inventors of the present invention have found out that when heat is applied to the package when surface-mounting the package to a mounting substrate such as a printed circuit board such as at the time of solder reflow, a moisture that has entered the package causes drastic volume expansion and peel of the package interface and crack develops.
[0007] To cope with this problem, it has been customary to bake the package at 125° C., for example, for a period as long as 16 to 24 hours before solder reflow, but this method is believed inefficient because a furnace for baking must be prepared and particularly because baking must be made for the long period.
[0008] As a result of examination of the origin of the moisture causing the crack described above, the inventors of the invention have clarified that the moisture in the air enters the package during the period from transfer mold of a chip component by a resin to solder reflow and is likely to dew.
[0009] Though the Otsuka et al. method described already provides a considerable effect, the problem cannot be solved completely by this method in view of the recent product situation where the thickness and size of the packages are reduced more and more to store greater chips and of the severe environment where the products are shipped by airplanes.
[0010] It is therefore an object of the present invention to provide a technique which prevents interface peel and crack of a surface mount package type package.
[0011] It is another object of the present invention to provide a highly reliable high density packaging technique.
[0012] It is still another object of the present invention to provide an efficient solder reflow technique.
[0013] It is still another object of the present invention to provide an effective shipment method of electronic components.
[0014] It is a further object of the present invention to provide an effective preservation method of semiconductor devices sealed by a thin resin package.
[0015] It is still another object of the present invention to provide high freedom for the conditions of executing an assembly process.
[0016] It is still another object of the present invention to provide an assembly process which will be suitable for surface mount package.
[0017] It is still another object of the present invention to provide an efficient surface mount type packaging technique.
[0018] It is still another object of the present invention to improve moisture-proofness of resin-molded ICs, or the like.
[0019] It is still another object of the present invention to provide a packaging technique of resin-molded ICs or the like which will be suitable for automatic packaging.
[0020] It is still another object of the present invention to provide a preservation method of ICs, components, electronic devices, and the like, which have high moisture-proofness and do not require baking even when stored for a long period.
[0021] It is still another object of the present invention to provide a packaging method of electronic components such as ICs which can easily discriminate the existence of pin-holes.
[0022] It is still another object of the present invention to provide a moisture-proofing packaging technique of ICs or the like which do not need a large space requirement.
[0023] It is still another object of the present invention to provide a moisture-proofing packaging technique of ICs or the like which can easily judge the degree of hygroscopicity of ICs or the like.
[0024] It is still another object of the present invention to provide a moisture-proofing bag having a display portion for displaying the degree of hygroscopicity of ICs or the like.
[0025] It is still another object of the present invention to provide a package member for a surface package type packages which can easily represent the degree of hygroscopicity of ICs or the like.
[0026] It is still another object of the present invention to provide an efficient surface mounting method of resin-molded ICs or the like.
[0027] It is still another object of the present invention to provide an assembly process which will be suitable for resin-molded electronic components storing therein integrated circuits having a large chip size.
[0028] It is still another object of the present invention to provide a shipment method of electronic devices such as resin-molded ICs which will be suitable for the shipment of the electronic devices by air planes.
[0029] It is still another object of the present invention to provide a moisture-proofing packaging technique of resin-molded ICs or the like which does not undergo dewing even at low temperatures.
[0030] It is still another object of the present invention to provide a technique which can confirm the state of hygroscopicity of a moisture-proofing package inside the package from the outside thereof.
[0031] These and other objects and novel features of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
[0032] Among the inventions disclosed herein, a typical example is as follows.
[0033] In the present invention, a surface mount package type package stored in a magazine is put into an interior box, the interior box is then placed into a transparent resin bag using, as the base, a polyester having moisture permeability of up to 2.0/m 2 ·24 hrs, for example, and having a surface intrinsic resistance of 10 6 Ohms on the outside and up to 10 11 Ohms on the inner side, and the open portion of the bag is heat-sealed after removing the air. Furthermore, a desiccant such as silica gel is put into the interior box.
[0034] According to this arrangement described above, the surface mount package type package is stored in the interior box and the moisture-proofing bag outside the box and sealed completely by deaeration and heat seal and is free from the influences of external moisture. Therefore, the interface peel and crack of the package do not occur even after solder reflow without the need of the troublesome baking operation. Particularly because the polyester having moisture permeability of up to 2.0 g/m 2 24 hours is used as the base of the resin bag in the present invention, moisture-proofness is high and heat seal is possible so that the effect of checking intrusion of the external air is high. The surface intrinsic resistance of the bag is up to 10 11 ohms on its inner surface and up to 10 6 ohms on its outer surface in order to prevent any charge. Furthermore, silica gel is placed between the magazine and the wall surface of the interior box in the present invention in order to absorb the moisture so that the surface package type package is not much affected by the external moisture.
[0035] Still another example of the inventions disclosed herein is as follows.
[0036] Namely, the present invention provides a transparent moisture-proofing packaging bag for moisture-proofing and packaging an electronic component, which bag is equipped with a moisture indicator for detecting the degree of hygroscopicity inside the moisture-proofing bag at a portion which is visible from outside.
[0037] According to the means described above, since the moisture indicator for detecting the moisture inside the transparent moisture-proofing bag is disposed at a position visible from outside, the degree of hygroscopicity of the bag can be confirmed from outside the bag.
[0038] Still another typical example of the inventions disclosed herein provides a package which comprises a semiconductor chip on which at least one electronic device is formed, a resin-molding member covering at least a part of the main plane of the semiconductor chip, and a moisture-proofing bag comprising a multi-layered film containing at least one metal sheet, for cutting off the resin-molding member from outside.
[0039] Still another typical example of the inventions disclosed herein provides a package of a number of (about 10) resin-molded semiconductor devices which are stored in a plastic magazine, whose outside portion is sealed air-tight by a moisture-proofing film.
[0040] Still another typical example of the inventions disclosed herein provides an air-tight package made of a moisture-proofing film and including a number of resin-molded semiconductor devices, a plurality of device storing magazines storing therein a line of resin-molded semiconductor devices, an interior box for aligning a plurality of magazines and storing them therein while they are in close contact with one another, a packaging bag made of a moisture-proofing sheet member, storing therein the interior box and sealed air-tight, and a desiccant placed in the packaging bag.
[0041] Still another typical example of the inventions discloses herein provide an air-tight package for a number of surface mount package type resin-molded semiconductor devices which comprises an exterior box made of a cardboard, a number (at least five to six) of packaging bags made of a moisture-proofing film and sealed air-tight, a plurality of interior boxes made of paper and stored in the packaging bag, a plurality of tube-like magazines for conveying semiconductor devices, stored in the interior boxes, respectively, a number of surface package type resin-molded semiconductor integrated circuit devices stored in the magazines, respectively, and a desiccant stored in each of the interior boxes.
[0042] Still another typical example of the inventions disclosed herein provides an air-tight package for a large number of surface mount package type resin-molded semiconductor integrated circuit devices which comprises an exterior box made of cardboard, a plurality of packaging bags made of a moisture-proofing film and sealed air-tight inside the exterior box, at least one conveying auxiliary member for protecting a number (at least five to six) of resin-molded semiconductor devices stored in the packaging bags, a number of resin-molded semiconductor integrated circuit devices stored in or on the auxiliary member, and a desiccant stored in each of the packaging boxes.
[0043] Still another typical example of the inventions disclosed herein provides an air-tight package for at least one resin-molded semiconductor device which comprises a packaging bag made of a moisture-proofing film, at least one conveying auxiliary member stored in the packaging bag, at least one resin-molded semiconductor device stored in the packaging bag and stored in or on the auxiliary member, and a desciccant placed in the packaging bag.
[0044] Still another typical example of the inventions disclosed herein provides an air-tight package for at least one resin-molded semiconductor device which comprises a packaging bag made of a moisture-proofing film and sealed air-tight, at least one resin-molded semiconductor device stored in the packaging bag, and a desiccant placed in the packaging bag.
[0045] Still another typical example of the inventions disclosed herein provides an air-tight package for at least one resin-molded semiconductor device which comprises a packaging bag made of a moisture-proofing film and sealed air-tight, at least one resin-molded semiconductor device stored in the packaging bag, and a desiccant stored in the packaging bag or formed on the inner surface of the packaging bag.
[0046] Still another typical example of the inventions disclosed herein provides a package comprising a semiconductor chip on which at least one electronic device is formed, a moisture-proofing bag for cutting off the semiconductor chip from outside, and humidity display means disposed in the moisture-proofing bag and capable of being recognized from inside.
[0047] Still another typical example of the inventions disclosed herein provides a package comprising a tube-like magazine for storing a line of a number (at least five to six) of resin-molded semiconductor devices, a number of resin-molded semiconductor devices stored in the magazine, and humidity display means disposed in the magazine in such a manner as to be visible from outside.
[0048] Still another typical example of the inventions disclosed herein provides a package for a large number (at least ten) of resin-molded semiconductor devices, sealed air-tight by a moisture-proofing film, said package being equipped thereinside with humidity display means in such a manner as to be visible from outside.
[0049] Still another typical example of the inventions disclosed herein provides an air-tight package made of a moisture-proofing film, which comprises a number of resin-molded semiconductor devices, a plurality of device storing magazines for storing therein a number of resin-molded semiconductor devices aligned in a line, an interior box for storing therein a plurality of magazines while being aligned and in close contact with one another, a packaging bag for storing therein the interior box, made of a moisture-proofing sheet and sealed air-tight, and humidity display means disposed inside the packaging bag in such a manner as to be visible from outside.
[0050] Still another typical example of the inventions disclosed herein provides an air-tight package for a number of surface package type resin-molded semiconductor integrated circuit devices, which comprises an exterior box made of cardboard, a number (at least five to six) of packaging bags made of a moisture-proofing film, sealed air-tight and stored in the exterior box, a plurality of interior boxes made of paper and stored in the packaging bag, a plurality of tube-like magazines for conveying semiconductor devices, stored in the interior boxes, respectively, a number of surface mount package type resin-molded semiconductor integrated circuit devices stored in a plurality of magazines, respectively, and humidity display means for displaying an internal humidity of said packaging bag, disposed inside the packaging bag in such a manner as to be visible from outside the packaging bag.
[0051] Still another typical example of the inventions disclosed herein provides an air-tight package for a number of surface package type resin-molded semiconductor integrated circuit devices which comprises an exterior box, a plurality of packaging bags made of a moisture-proofing bag and stored in the exterior box, at least one conveying auxiliary member for protecting a number (five to six) of resin-molded semiconductor devices stored in the packaging bag, a number of resin-molded semiconductor integrated circuit devices stored in or on the auxiliary member, and humidity display means for displaying the internal humidity of the packaging bag, disposed in the packaging bag in such a manner as to be visible from outside.
[0052] Still another typical example of the inventions disclosed herein provide an air-tight package for at least one resin-molded semiconductor device, which comprises a packaging bag made of a moisture-proofing film and sealed air-tight, at least one conveying auxiliary member stored in the packaging bag, at least one resin-molded semiconductor device stored in the packaging bag and stored in or on the auxiliary member, and humidity display means disposed in the packaging bag in such a manner as to be visible from outside.
[0053] Still another typical example of the inventions disclosed herein provides an air-tight package for at least one resin-molded semiconductor device, which comprises a packaging bag made of a moisture-proofing bag and sealed air-tight, at least one resin-molded semiconductor device stored in the packaging bag, and humidity display means disposed in the packaging bag in such a manner as to be visible from outside.
[0054] Still another typical example of the inventions disclosed herein provides an air-tight package for at least one resin-molded semiconductor device, which comprises a packaging bag made of a moisture-proofing film and sealed air-tight, at least one resin-molded semiconductor device stored in the packaging bag, and a drying member stored or formed inside the packaging bag in such a manner as to be visible from outside.
[0055] Still another typical example of the inventions disclosed herein provides an air-tight package for a number of resin-molded semiconductor devices, which comprises a carrier tape made of a first moisture-proofing resin sheet and having device storing recesses, a plurality of resin-molded semiconductor devices stored in the recesses, and a second moisture-proofing resin sheet covering the upper surface of the recesses and sealed in such a manner as to keep the inside of the recesses air-tight.
[0056] Still another typical example of the inventions disclosed herein provides a packaging method of resin-molded semiconductor devices, which comprises the steps of preserving the resin-molded devices in a moisture-proofing bag lest they should absorb moisture, taking out the resin-molded devices from the moisture-proofing bag, and placing the resin-molded devices on a wiring substrate and soldering the leads of the resin-molded devices to the wirings on the wiring substrate under such a condition where the resin-molded portion receives thermal impact.
[0057] Still another typical example of the inventions disclosed herein provides a method of shipping a large number of resin-molded semiconductor devices by an air plane, which comprises sealing air-tight the resin-molded semiconductor devices together with a desiccant in a moisture-proofing bag.
[0058] Still another typical example of the inventions disclosed herein provides a method of fabricating resin-molded semiconductor devices, which comprises the steps of sealing a semiconductor chip and inner leads by a resin, putting an ink mark to the resulting resin-molded member, exposing the resin-molded member as a whole after marking to a high temperature for baking the ink, and sealing airtight the devices after completion before they absorb moisture.
[0059] Still another typical example of the inventions disclosed herein provides a method of fabricating a semiconductor memory device, which comprises the steps of fixing lead to semiconductor chip holding portions made of the same metal sheet as that of the leads through one of the main planes of the tip, bonding pads on the other main plane of the chip to inner leads by a bonding wire, coating an organic resin causing less occurrence of a-rays on at least a region of the other main plane of the chip, where memory cells are formed, forming a resin-molded member from which a plurality of leads projects, by molding the chip, the wires, the chip holding members and the inner leads by a resin, and packaging the resin-molded member by a moisture-proofing bag lest the resin-molded member absorbs the moisture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0060] [0060]FIG. 1 is a perspective view of a package in accordance with the first embodiment of the present invention;
[0061] [0061]FIG. 2 is a perspective view of an interior box in the first embodiment described above;
[0062] [0062]FIG. 3 is a perspective view showing an example of a magazine;
[0063] [0063]FIG. 4 is an explanatory sectional view of the end portion of the magazine;
[0064] [0064]FIG. 5 is an explanatory view of an example of a bag;
[0065] [0065]FIG. 6 is a perspective view showing the appearance and construction of a transparent moisture-proofing packaging bag in accordance with the second embodiment of the present invention;
[0066] [0066]FIG. 7 is an enlarged sectional view taken along line II-II of FIG. 6 and shows the fitting portion of a humidity indicator fitted to the inner side surface of a transparent bag-like moisture-proofing member;
[0067] [0067]FIG. 8 is a partially cut-away perspective view showing the structure of the transparent bag-like moisture-proofing member of the moisture-proofing bag shown in FIG. 6;
[0068] [0068]FIG. 9 is a perspective view showing the appearance and construction of a transparent moisture-proofing packaging bag in accordance with the third embodiment of the present invention;
[0069] [0069]FIG. 10 is an enlarged sectional view taken along line II-II of FIG. 9 and is an enlarged sectional view of a humidity indicator fitted to the inner side surface of a transparent bag-like moisture-proofing member;
[0070] [0070]FIG. 11 is a partially cut-away perspective view showing the structure of an opaque bag-like moisture-proofing member of the moisture-proofing packaging bag shown in FIG. 9;
[0071] FIGS. 12 to 17 are sectional views showing the appearance of resin-molded semiconductor devices to which the first to third embodiments of the present invention are applied;
[0072] FIGS. 18 to 21 show examples of conveying auxiliary members used in the first to third embodiments of the present invention, respectively;
[0073] [0073]FIG. 22 is an explanatory view showing in detail the packaging method in the first to third embodiments of the present invention;
[0074] [0074]FIG. 23 is a sectional view of a memory IC device dealt with in the first to third embodiments of the present invention;
[0075] [0075]FIG. 24 is a schematic view showing the completed state of surface packaging in the first to third embodiments of the present invention; and
[0076] [0076]FIG. 25 is a schematic view of a solder dipping method of a similar package.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0077] Hereinafter, the present invention will be described more definitely with reference to some preferred embodiments thereof shown in the accompanying drawings.
[0078] [Embodiment 1]
[0079] A magazine 2 is stored in an interior box 1 made of paper, as shown in FIG. 2. An example of the magazine is shown in FIG. 3. A surface mount package type semiconductor package 3 is packaged into the magazine 2 and a stopper 4 is fitted to the end portion of the magazine 2 in order to prevent projection of the package 3 from the magazine 2 .
[0080] A plurality of packages 3 are packaged into the magazine 2 .
[0081] Silica gel 5 is put between the wall of the interior box 1 and the side surfaces of the magazine 2 as shown in FIG. 2. Preferably, the silica gel 5 is put into the end portions of the magazine for absorbing moisture. A flange 7 of a lid 6 is folded inward and the lid 6 is closed. When the package 3 is taken out by lifting up the lid 6 , the end open side of the lid 6 is first affected by external moisture. For this reason, it is advisable to place the silica gel on the open side of the lid.
[0082] The interior box 1 is put into a bag 8 such as shown in FIG. 5 and after deaeration, the open portion 9 of the bag 8 is heat-sealed.
[0083] The bag 8 is made of a transparent, electrically conductive bag using a polyester having moisture 2 permeability of up to 2.0 g/m 2 ·24 hrs as the base.
[0084] If the bag 8 is transparent, it is very convenient for the management of the products because the kind of products, quantity, production lot number, and so forth, are put usually on the surface of the interior box 1 .
[0085] An example of the resin films constituting the conductive bag 8 is a laminate film prepared by laminating a polyethylene containing an antistatic agent kneaded therein, a polyester film, a carbon conductive layer and an acrylic resin protective film in order named from the inside, and further coating a vinylidene chloride film on the laminate. To prevent charge of IC(s) inside the package 8 , the surface intrinsic resistance of the conductive bag 8 is up to 10 6 ohms on the outer surface and up to 10 11 ohms on the inner surface.
[0086] Cautions to the effect that the devices should be used rapidly after opening the bag and the bag should be kept in the environment of low humidity are printed on the surface of the conductive bag 8 or a label 10 bearing such cautions is bonded to the conductive bag 8 .
[0087] In accordance with the present invention, the surface mount package type package 3 is kept in the moisture-proofing bag 8 and is sealed completely by deaeration and heat seal 9 . Since the silica gel 5 absorbs the moisture on the opening side and the package 3 is not affected by the external moisture, a troublesome baking operation becomes unnecessary and even after solder reflow, peel of interface and crack of the package can be prevented.
[0088] Other desiccants can be used in the embodiment described above in place of silica gel.
[0089] [Embodiment 2]
[0090] A second embodiment of the present invention will be explained definitely with reference to the drawings.
[0091] In FIGS. 6 to 8 useful for explaining this embodiment, like reference numerals are used to identify like constituents and repetition of explanation of their function will be omitted.
[0092] [0092]FIG. 6 is a perspective view showing the appearance and structure of a transparent moisture-proofing packaging bag of this embodiment.
[0093] As shown in FIG. 6, the transparent moisture-proofing packaging bag of this embodiment is made of a transparent bag-like moisture-proofing member 11 . A plurality of electronic components 12 such as surface mount package type semiconductor devices are stored in a container 13 and the containers 13 are stored in an interior box 14 . Furthermore, the interior box 14 is stored in the bag-like moisture-proofing member 11 , and both of its end portions 11 A, 11 B are sealed. When moisture-proofing packaging is made, a humidity indicator 15 for detecting the humidity inside the moisture-proofing packaging bag 17 is disposed on the inner side surface of the transparent bag-like moisture-proofing member 11 at a position where the indicator 15 can be seen from outside.
[0094] Examples of this humidity indicator 15 are as follows.
[0095] 1. A caution is printed on the inner side surface of the transparent bag-like moisture-proofing member 11 by an ink containing a material which changes the color by moisture, such as cobalt chloride, which serves as the humidity indicator 15 . For example, the caution reads as “When the color of this caution changes from blue to thin violet, take out surface package type semiconductor devices from the bag and bake them at 125° C. for 24 hours”.
[0096] 2. As shown in FIGS. 6 and 7, the humidity indicator (humidity detection label) 15 is bonded to the inner side of the transparent bag-like moisture-proofing member 11 by an adhesive 16 having vent holes 16 A so that it can be confirmed from outside. This humidity detection label is prepared, for example, by letting paper made of a pulp absorb a material which changes color by humidity, such as cobalt chloride.
[0097] 3. As shown in FIG. 6, the humidity indicator (humidity detection label) 15 is bonded to the interior box 14 inside the moisture-proofing packaging bag 17 or the caution is printed there by the material which changes color by moisture such as cobalt chloride.
[0098] Incidentally, when the humidity indicator (humidity detection label) 15 is bonded in the items 2 and 3 described above, there is no need to print the caution by the material which changes the color such as cobalt chloride.
[0099] Next, the structure of the transparent bag-like moisture-proofing member 11 comprises a laminate sheet as shown in FIG. 8.
[0100] In FIG. 8, reference numeral 18 represents a polyethylene layer into which an antistatic agent is kneaded. This is the innermost layer of the moisture-proofing packaging bag 17 . The polyethylene layer 18 containing the antistatic agent is 63 μm-thick, for example, and has the functions of preventing frictional charge, heat sealability, openability, and so forth. A polyester film layer 19 having a pin-hole proofing function is disposed on the polyethylene layer 18 containing the antistatic agent. A polyester film layer 20 having a barrier layer for preventing intrusion of moisture is disposed on the polyester film layer 19 . The barrier layer 20 is prepared, for example, by coating a vinylidene chloride film on a 14 μm-thick polyester film. A polyester film layer 21 (which is 12 μm thick) is disposed on the barrier layer 20 prepared by coating vinylidene chloride on the polyester film (14 μm thick), and a 1 μm thick, for example, carbon conductive layer 22 is disposed on the polyester film 21 . The polyester film 21 has the function of reinforcing mechanical strength and dielectric resistance while the carbon conductive layer 22 has the function of preventing charge. The carbon conductive layer 22 is devoid of degradation with time and does not have humidity dependence. The material of the protective layer 23 has properties such that it protects the carbon conductive layer 22 , prevents the occurrence of carbon flake dust and has high abrasion resistance and printability.
[0101] Next, the method of using the humidity indicator 15 in the moisture-proofing packaging bag 17 will be explained briefly.
[0102] First of all, the bag-like moisture-proofing member 11 which is equipped with the humidity indicator 15 for detecting the internal humidity of the moisture-proofing package 17 on the inner side surface of the transparent bag-like moisture-proofing member 11 at a position where the indicator is visible from outside is prepared, as shown in FIG. 7.
[0103] A plurality of containers 13 storing therein a plurality of electronic components 12 such as surface package type semiconductor devices are put into the interior box 14 , the interior box 14 is then put into the bag-like moisture-proofing member 11 and its both end portions 11 A and 11 B are sealed for moisture-proofing packaging.
[0104] If the color of the humidity indicator 15 or the caution changes from blue to thin violet at the time of use of the electronic components 12 such as the surface mount package type semiconductor devices, the electronic components 12 are taken out from the moisture-proofing packaging bag 17 , are then baked at 125° C. for 24 hours and packaging is then made by solder reflow, infrared lamp or vapor phase reflow.
[0105] As can be understood from the description given above, since this embodiment disposes the humidity indicator 15 for detecting the internal humidity of the transparent moisture-proofing bag 17 at the position where it is visible from outside, the state of hygroscopicity inside the bag 17 can be confirmed from outside the bag. Accordingly, management of the moisture-proofing bags 17 can be made easily.
[0106] This embodiment can be applied to packaging of all those electronic components other than the surface mount package type semiconductor devices described above which are affected by humidity.
[0107] [Embodiment 3]
[0108] The third embodiment of the present invention and a semiconductor process which is common to the foregoing two embodiments will be explained with reference to the drawings.
[0109] Hereinafter, the description will be made primarily on DRAM by way of example.
[0110] (1) Fabrication Process in General:
[0111] Since the structure and processes of the semiconductor chip (DRAM, logic IC) as the essence of the semiconductor devices (integrated circuit devices, electronic devices) dealt with in the present invention are described in U.S. Pat. No. 4,612,565 (U.S. Ser. No. 783,531, filed Oct. 3, 1985) and U.S. Pat. No. 4,625,227 (U.S. Ser. No. 744,151, filed Jun. 13, 1985). Therefore, the description will be made by referring partly to these references.
[0112] After a wafer step is complete, a wafer is split into each chip by dicing using a rotary blade. The fabrication steps before and after the wafer step are described in “Electric Integrated Circuits”, John Allison, 1975, by McGraw Hill Book Company, pp. 5-10, particularly in Fig. 1.3 (p. 7). As to the dicing technique, refer to U.S. Pat. No. 4,016,855 (U.S. Ser. No. 608,733, field Aug. 28, 1975).
[0113] Thereafter, each chip is die-bonded to a lead frame. For detail of die-bonding of various kinds of chips, refer to U.S. patent application Ser. No. 256,110 (filed Apr. 21, 1981), U.S. patent application Ser. No. 874,121 (filed Jun. 13, 1986), U.S. patent application Ser. No. 845,332 (filed Mar. 21, 1986), U.S. patent application Ser. No. 843,611 (filed Mar. 25, 1986), U.S. patent application Ser. No. 898,534 (filed Aug. 21, 1986), U.S. patent application Ser. No. 740,420 (filed Jun. 3, 1985), U.S. patent application Ser. No. 758,030 (filed Jul. 23, 1985) and U.S. patent application Ser. No. 767,598 (filed Aug. 20, 1985).
[0114] Next, each bonding pad of each pellet and the inner lead terminal of the lead frame are bonded by a bonding wires (about 30 μm thick) of Cu, Al, Au, or the like. Besides the various U.S. patents and patent applications described above, refer also for the detail of this bonding technique to U.S. Pat. No. 4,564,734 (U.S. Ser. No. 476,268, filed Mar. 17, 1983), U.S. Pat. No. 4,301,464 (U.S. Ser. No. 55,070, filed Jul. 5, 1979), U.S. patent application Ser. No. 898,535 (filed Aug. 21, 1986), and U.S. patent application Ser. No. 723,645 (filed Apr. 16, 1985).
[0115] Furthermore, an about 20 to 200 μm-thick high purity polyimide layer or silicon resin layer is formed by potting on the chip after completion of bonding in order to prevent any soft errors by α-rays. For the detail of resin coating, refer to U.S. patent application Ser. No. 256,110. Resin coating for preventing the α-ray soft error may be carried out during the wafer process. At this time, a suitable thickness is from about 10 μm to about 80 μm and the resin coating is formed by the combination of spin coating with photolithography in such a manner as to cover at least the memory cell mat.
[0116] After wire bonding is complete, the lead frame is molded into an epoxy resin material by transfer mold. As to the molding technique, refer to various U.S. patents and patent applications described above as well as to “VLSI Technology”, S. M. Sze, 1983, by McGraw-Hill Book Company, pp. 574-581.
[0117] After molding is complete, the lead frame is withdrawn from the molding die and after any fins on the lead are completely removed, the unnecessary portions of the lead frame are cut off, the molded member is cut away from the frame and the leads are shaped in a desired shape.
[0118] After these steps, the products are selected and marking is applied to the approved products. This marking step may be made before cutting the leads. In other words, Sn or the like is plated to the surface of the exposed lead frame after resin molding by electroplating. Thereafter, the resin molded member and the exposed surface of the lead frame are cleansed (washed with water) to remove the plating solution attaching to them, and after they are dried, they are put to an automatic marking machine for applying the mark.
[0119] In this marking, marks representing the kind of products, class, and the like, are simultaneously put to the resin-molded member such as MOS semiconductor devices by offset marking using a rotary drum (transfer drum) or relief direct mark while the lead frame to which a plurality of semiconductor devices are fixed is moved in a predetermined direction. At this time, static electricity develops between the transfer drum or the relief and the resin molded member, but since the frame is kept as a whole at the same potential, the static electricity does not affect the interior of the semiconductor pellet but is grounded. Thereafter, the printed marks are baked or dried by a ultraviolet or infrared dryer or mere heat-treatment and adhered tightly to the resin molded member.
[0120] Thereafter, each semiconductor device is separated by punching, cutting and bending and each lead of each MOS semiconductor device or the like becomes simultaneously an independent lead. The leads are bent in the L-shape on the same side and a dual-in type MOS semiconductor device or the like free from dielectric breakdown is thus completed.
[0121] As described above, baking (mark baking) is made at 150° C. for 3 to 5 hours in the case of marking by the ink. If laser marking is employed, on the other hand, baking for drying the ink is not particularly required. For the detail of laser marking, refer to U.S. patent application Ser. No. 720,884 (filed Apr. 8, 1985).
[0122] After baking is complete, the resin molded electronic devices (such as integrated circuit devices, semiconductor devices) are put into the moisture-proofing bag shown in the foregoing two embodiments, either directly or through a suitable auxiliary member (magazine, tray, tape, reel, etc.), within a few days and preferably, within a few hours after completion, together with a desiccant such as silica gel, and are then sealed air-tight.
[0123] Thereafter, the resin molded devices are packed into a shipment cardboard box or the like for shipment while being sealed in the bag.
[0124] These semiconductor devices are taken out from the moisture-proofing bag immediately before mounting. In an ordinary environment, they are taken out within two to three days or within a few hours, before use. The inventors of this invention found out that if they are exposed to the external air for more than one week, they absorb substantially completely the moisture in the external air. Various solder reflow processes are used for mounting the semiconductor devices.
[0125] (2) Detail of Moisture-Proofing Bag and its Film:
[0126] [0126]FIG. 9 is a perspective view showing the appearance and structure of an opaque moisture-proofing bag of this embodiment.
[0127] As shown in FIG. 9, the opaque moisture-proofing packaging bag of this embodiment is made of an opaque bag-like moisture-proofing member 11 . A plurality of electronic components 12 such as surface mount package type semiconductor devices are put into a container 13 and the containers 13 are then stored in the interior box 14 . After this interior box 14 is put into the baglike moisture-proofing member 31 , its both end portions 32 A and 32 B are sealed for moisture-proofing. When moisture-proofing packaging is made, the humidity indicator 15 for detecting the internal humidity of the moisture-proofing bag 31 is disposed on the inner side surface of the opaque bag-like moisture-proofing member 31 at a position where it is visible from outside.
[0128] Next, an example of this humidity indicator 15 will be given.
[0129] Cautions are printed on the inner side surface of the transparent bag-like moisture-proofing member 31 by an ink containing a material which changes the color by humidity, such as cobalt chloride. The caustions read, for example, as “If the color of the cautions change from blue to thin violet, take out the surface mount package type semiconductor devices from the moisture-proofing packaging bag and bake them at 125° C. for 24 hours”.
[0130] As shown in FIGS. 9 and 10, the peripheral portion of the humidity indicator (humidity detection label) 15 is bonded directly to the inside of a transparent window 33 disposed at a part of the opaque moisture-proofing member 31 by an adhesive so that the indicator can be confirmed from outside. This humidity detection label is prepared, for example, by letting paper made of a pulp absorb a material which changes the color by humidity, such as cobalt chloride. For example, it is possible to let the portion of the surface of the interior box corresponding to the window 33 absorb such a material.
[0131] As shown in FIGS. 9 and 10, the humidity indicator (humidity detection label) 15 is printed on the interior box 14 of the moisture-proofing packaging bag 31 or the caution is printed there by the material which changes the color by humidity such as cobalt chloride.
[0132] When the humidity indicator (humidity detection label) 15 is bonded, there is no need to print the caution by the material changing the color by humidity, such as cobalt chloride.
[0133] Next, the moisture-proofing member 34 at the transparent window portion of the moisture-proofing packaging bag comprises a laminate sheet as shown in FIG. 8.
[0134] On the other hand, the portions of the moisture-proofing bag other than the transparent window 33 shown in FIG. 10 is made of an opaque sheet having an aluminum film 35 as shown in FIG. 11.
[0135] In FIG. 11, reference numeral 36 represents a polyethylene layer into which an antistatic agent is kneaded and which serves as the innermost layer of the moisture-proofing packaging bag 31 . The polyethylene layer 36 containing the antistatic agent is 60 μm thick, for example, and has the functions of preventing frictional charge, heat sealability, openability, and the like.
[0136] An aluminum foil 35 having high moisture-proofness is spread on this polyethylene layer 36 . Since aluminum is a metal, its vapor permeability is extremely lower than that of organic films and can effectively prevent its intrusion. This aluminum is about 10 μm thick, for example. Furthermore, an about 20 μm-thick polyethylene film layer 39 having high heat moldability is disposed on this aluminum. A polyester film layer (which is 12 μm thick) 38 having high mechanical strength and high withstand voltage is disposed on the polyethylene film and a 1 μm-thick carbon conductive layer 37 is disposed on the polyester film layer. Furthermore, an acrylic type protective layer 40 is disposed on the carbon conductive layer 37 . The polyester film layer 38 has the function of reinforcing mechanical strength and dielectric resistance while the carbon conductive layer 37 is devoid of degradation with time and does not have humidity dependence. The material of the protective layer 40 has properties such that it protects the carbon conductive layer 37 , prevents the carbon flake dust and has high abrasion resistance and high printability.
[0137] Next, the method of using the humidity indicator 15 in the moisture-proofing packaging bag 31 of this embodiment will be explained briefly.
[0138] First of all, the bag-like moisture-proofing member 31 which is equipped with the humidity indicator 31 disposed at the position of the transparent window 33 , where the indicator is visible from outside, on the inner side surface of the moisture-proofing member 11 is prepared. A plurality of electronic components 12 such as the surface mount package type semiconductor devices are stored in the container 13 , the containers 13 are then stored in the interior box 14 and after the interior box 14 is put into the bag-like moisture-proofing member 11 , its both end portions 32 A and 32 B are sealed for moisture-proofing.
[0139] When the color of the humidity indicator 15 or the caution changes from blue to thin violet when using the electronic components 12 such as the surface mount package type semiconductor devices, the electronic components 12 are taken out from the moisture-proofing bag 31 and baked at 125° C. for 24 hours. Thereafter, they are mounted by solder reflow, infrared lamp or vapor phase reflow.
[0140] As can be understood from the description given above, this embodiment disposes the humidity indicator 15 for detecting the internal humidity of the opaque moisture-proofing bag 31 at the position where it is visible from outside. Accordingly, the internal state of hygroscopicity of the bag 31 can be confirmed from outside and its management can be made easily. Since the moisture-proofing bag 31 is not broken, re-packaging is not necessary after confirmation.
[0141] This embodiment can be changed or modified in various manners.
[0142] For example, the embodiment can be applied to all those electronic components other than the surface mount package type semiconductor devices described above which are affected by the influence of humidity.
[0143] (3) Detail of Resin Molded Electronic Devices as Object of Application:
[0144] [0144]FIG. 12 shows a package which is called a “gull wing” and generally a “Small Outline Package (SOP)”.
[0145] [0145]FIG. 13 shows a surface mount package type package which is called a “flat plastic package (FPP) or a squad flat package (QFP)”. Furthermore, FIG. 14 shows a package for use specially for a memory or the like, which is called a “small outline J-bend package (SOJ)”. FIG. 15 shows a package which is called a “plastic leaded chip carrier (PLCC)” and is used for high density surface mount package. FIG. 16 shows a package which belongs to a butt lead type and is called a “mini-squad package (MSP)”.
[0146] Unlike the packages shown already, the package shown in FIG. 17 is of a type in which leads are fitted into holes of a substrate. Therefore, it belongs to an insert type and is generally called a “dual in-line package (DIP)”.
[0147] In FIGS. 12 to 17 described above, the semiconductor chip 42 is fixed to a holder such as tabs or islands made of a thin metal sheet through an Ag paste 43 . The bonding pads on the chip and the inner leads having the Ag spot plating layer 44 formed thereon are subjected to ball and wedge bonding by capillary by an Au wire 45 (30 μm diameter), or the like. The leads 46 are formed by punching out from a 42 -alloy or a copper alloy film. They are transfer-molded by an epoxy resin 41 .
[0148] (4) Detail of Conveying Auxiliary Member:
[0149] A large number of resin molded devices are stored in various conveying auxiliary member and are then sealed air-tight depending upon their applications.
[0150] The auxiliary member will now be explained.
[0151] [0151]FIG. 18 shows the state of a magazine 54 and the resin molded devices (transistors, ICs, LSIs, etc.) stored in the magazine 54 . MSP type resin molded devices 53 are stacked vertically inside the magazine 54 and a polyethylene sub-stopper 52 and a main stopper made of hard nitrile rubber are packed into the end portion of the magazine. The magazine main body is made of hard polystylol containing carbon or electrically conductive soft vinyl chloride.
[0152] [0152]FIG. 19 shows a tray 55 as one of the auxiliary members. The tray is made of vinyl chloride to which antistatic treatment is applied, and the resin molded devices 53 are put into square recesses 56 that are aligned in the form of array. In this case, it is possible to put directly silica gel or the like into each recess 56 and to seal the upper surface air-tight by the moisture-proofing sheet. Generally, after the trays are stacked, they are put into the interior box made of paper and then sealed into the moisture-proofing bag.
[0153] [0153]FIG. 20 shows an auxiliary member which is called a “tape and reel” system. The resin molded devices 53 are held in a line on a carrier tape 57 wound on a reel 59 through an adhesive tape 58 . After the carrier tape 57 is wound on the reel 59 , the reel is sealed air-tight one by one in the moisture-proofing bag.
[0154] [0154]FIG. 21 shows another type of the tape and reel system. In this case, the resin molded devices 53 are stored in the square recesses 56 formed in a line on the carrier tape 57 and their upper surface is heat-sealed by a cover tape 60 . The tape is wound on the reel under this state and the reel is sealed moisture-tight in the same way as above. In this case, too, the external moisture-proofing sheet can be eliminated by changing the cover tape 60 to the moisture-proofing sheet shown in FIG. 8 or 11 and putting silica gel or the like into each recess 56 .
[0155] Incidentally, refer to U.S. patent application Ser. No. 879,012 (filed Jun. 26, 1986) for the detail of production of magazine and the like.
[0156] (5) Detail of Shipment Package of ICs or the Like:
[0157] [0157]FIG. 22 shows an example of a shipment package of resin molded devices 53 (plug-in type or surface mount package type devices). A number of resin molded devices 53 are stored in a line inside the tube-like magazine 2 and secured fixedly by a stopper pin 64 and a stopper filler 4 . A predetermined number of magazines are stored in the interior box 1 having low hygroscopicity, made of paper or sheet and stored inside the bag made of the moisture-proofing sheet such as shown in FIG. 8 or 11 . The internal pressure of the bag becomes somewhat lower than that of the external air and deaeration is made so that the moisture-proofing bag comes substantially into close contact with the outer surface of the interior box and air-tight sealing is then made by pressurization or by heating. In this manner, the interior boxes can be stored easily in the exterior box and the storage space becomes small.
[0158] On the other hand, the existence of any pin-holes can be descriminated easily by putting dry N 2 , which may be somewhat pressurized, into the bag in order to secure a gap between the moisture-proofing sheet and the interior box.
[0159] Though the description given above primarily deals with the magazine by way of example, packaging can be made substantially in the same way as above in the case of the tray and the tape and reel. In addition, either one or a plurality of the resin molded ICs may be put directly into the moisture-proofing bag.
[0160] It is also possible to put and seal the auxiliary member directly into the moisture-proofing bag without using the interior box.
[0161] Though the desiccant is put into a paper bag or the like and then placed inside the interior box, it may be placed at a suitable air-tight position such as the recess of the magazine or the carrier tape. For instance, the desiccant may be coated and diffused on the inner surface of the moisture-proofing sheet.
[0162] As described above, a predetermined number of moisture-proofing bags that have been sealed air-tight are stored in the exterior box 61 made of the cardboard and sealed by the adhesive tape 62 . After the box is bound by bands 63 , the box is shipped.
[0163] As to other air-tight sealing methods, particularly the method-which uses the tray, refer to the afore-mentioned reference Japanese Patent Laid-Open No. 178877/1986.
[0164] (6) Detail of Memory Chips and DRAM Devices:
[0165] The relationship between the sectional structure of the memory IC device and the package in the present invention will be explained. Here, the SOP type package will be described by way of example.
[0166] In FIG. 23, a very large number (about 1,000,000) of FETs constituting DRAM are formed on the upper main plane of the Si substrate 71 . On the Si substrate are formed field oxide films forming these devices, insulation films (inorganic films) 72 made of an inter-level PSG (phospho silicate glass), and the like. A number of Al bonding pads 75 are disposed further thereon.
[0167] On the other hand, the Si substrate 71 is fixed on its lower main plane to the islands or tabs 78 through the Ag paste 77 . The size of this chip 71 is about 10 mm×5 mm×0.4 mm (high×wide×thick). The lead 80 is made of the same 42 -alloy as that of the islands, and partial Ag plating 79 is disposed at the inner lead portion. After ball and wedge bonding is made to the gap between the inner end of the lead 80 and the bonding pad by an Au wire having a 30 μm diameter, a polyimide resin 73 is formed by potting onto substantially the entire upper surface of the chip from above the former. Thereafter, the structure is transfer-molded by an epoxy resin 76 in a lead frame unit. Solder plating 81 is applied to the lead portions protruding from the mold resin 76 .
[0168] At this time, the 42-alloy member of the lead and island portion is 0.15 mm thick, the mold resin on the upper surface of the package is about 1 mm thick, the polyimide film is about 0.1 mm thick, the Ag paste is about 50 μm thick and the lower surface of the mold resin is about 1 mm thick.
[0169] In the package sealed by such a thin resin, if the absorbed moisture content is great, evaporation and expansion of the moisture occur first on the lower surface of the tab 78 due to drastic heating at the time of soldering and packaging. Subsequently, peel occurs between the resin and the metal and the package swells. The inventors found out that if the resin cannot withstand the resulting stress at this time, package crack develops.
[0170] (7) Detail of the Package Mounting Process:
[0171] First of all, the outline of the surface mounting process will be given.
[0172] Desired wirings are formed on the substrate made of glass-epoxy resin, or the like, by a Cu film or the like, and a solder past is formed by screen printing or the like at solder portions (foot print) on the substrate. Then, the resin molded devices are mounted onto the solder paste by a vacuum chuck or like means, and solder in the paste is fused for soldering by the solder reflow method such as vapor phase reflow, heating furnace, infrared reflow, and like means.
[0173] [0173]FIG. 24 shows the state of mounting. In the drawing, reference numeral 91 represents the resin molded device of the SOJ type, 92 is the resin molded device of the SOP type and 93 is the resin molded device of the MSP type. Reference numeral 94 represents the wiring substrate and 95 is the solder which is reflowed or dipped.
[0174] [0174]FIG. 25 shows the solder dipping method. As shown in FIG. 25( a ), the resin molded device 93 of the MSP type is fixed in such a manner that its leads are placed on the screen-printed solder paste on the substrate 94 by the adhesive 96 . Subsequently, it is dipped downwardly into the solder stream 98 as shown in FIG. 25( b ) and is then cooled in such a manner as to attain the state shown in FIG. 25( c ).
[0175] Though the present invention has thus been described with reference to some preferred embodiments thereof, it will be obvious to those skilled in the art that the invention is not particularly limited thereto but can be changed or modified in various manners without departing from the spirit and scope thereof. | In surface packaging of thin resin packages such as resin molded memory ICs or the like, cracks of the package occur frequently at a solder reflow step where thermal impact is applied to the package because the resin has absorbed moisture before packaging.
To solve this problem, the devices are packaged moisture-tight at an assembly step of the resin molded devices where the resin is still dry, and are taken out from the bags immediately before the execution of surface packaging. | 1 |
FIELD OF THE DISCLOSURE
[0001] The present disclosure is generally directed toward communications and more specifically toward unified communications.
BACKGROUND
[0002] In Unified Communication Federation deployment where there's a centralized broker to route signaling, a solution is needed to route the media directly between the two communicating entities (e.g., between a first enterprise and a second enterprise). If the media is routed through the centralized broker, the centralized broker has to provide large bandwidth to handle all of the media traffic. This is often cost-prohibitive to the centralized broker.
[0003] Some solutions have been described to shuffle signaling and media from the centralized broker to a Peer-to-Peer (P2P) network. U.S. application Ser. No. 13/250,008 to Krishnaswamy et al., the entire contents of which are hereby incorporated herein by reference, describes details of such a solution where a centralized broker is used by enterprises or different communicating entities to establish a trust relationship and then, after the trust relationship has been established, the entities move their communication session to a P2P network. Unfortunately, moving the communication session to a P2P network takes the centralized broker out of the signaling path, thereby preventing the centralized broker from offering additional services to the communicating entities during the communication session.
SUMMARY
[0004] It is with respect to the above issues and other problems that the embodiments presented herein were contemplated. In particular, embodiments of the present disclosure propose the ability to, among other things, establish the signaling channel from a first communicating entity (e.g., Enterprise A) to the centralized broker and also from the centralized broker to a second communicating entity (e.g., Enterprise B). After the signaling channel has been established between Enterprise A and B through the centralized broker, the broker is able to shuffle the media path so that media flows directly between Enterprise A and B. Any single type of media or combinations of media may be carried along the media path established between the enterprises including, without limitation, voice media, video media, web-content, data, images, graphics, and combinations thereof. This alleviates the centralized broker from having to purchase and maintain the required communications equipment that would otherwise be needed to support the media exchange between the communicating entities.
[0005] Some embodiments of the present disclosure utilize a centralized broker to direct different communicating entities (e.g., Enterprise A and Enterprise B or users from different enterprises) to set up the media channel according to the following: (1) broker sends Enterprise A the credentials or fingerprint of Enterprise B's credentials along with the information on how to connect to Enterprise B—this message or messages can be protected using RFC4474, the entire contents of which are hereby incorporated herein by reference; (2) broker sends Enterprise B the credentials or a fingerprint of Enterprise A's credentials along with the information on how to connect to Enterprise A—this message or messages can be protected using RFC 4474; and (3) Enterprise A and B establish a communication channel using the Datagram Transport Layer Security (DTLS) protocol to authenticate one another and exchange media encryption keys as well as the Internet Protocol (IP) address and port to use for the exchange of media.
[0006] Once the communicating entities have exchanged the necessary information, determined the IP address and port to use for the other entity, and established the media path there between, the communicating entities are capable of exchanging media directly with one another (e.g., without involving the broker in the media path). However, the control signaling exchanged between the communicating entities to control the media exchange may still pass through the centralized broker. This allows the centralized broker to remain aware of the communication session as well as possibly offer other services to the communicating entities during or after the communication session.
[0007] In accordance with at least some embodiments of the present disclosure, a method is provided which generally comprises:
[0008] receiving, at a communication broker, a request from a first communicating entity to establish a communication session with a second communicating entity;
[0009] providing information to the first communicating entity that will enable the first communicating entity to authenticate the second communicating entity as well as providing an address associated with the second communicating entity;
[0010] providing information to the second communicating entity that will enable the second communicating entity to authenticate the first communicating entity as well as providing an address associated with the first communicating entity; and
[0011] maintaining a control signaling path between the first and second communicating entities at the communication broker during at least a portion of a communication session between the first and second communicating entities even though a media path for the communication session is established directly between the first and second communicating entities.
[0012] The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
[0013] The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
[0014] The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material”.
[0015] The term “computer-readable medium” as used herein refers to any tangible storage that participates in providing instructions to a processor for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, magneto-optical medium, a CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, or any other medium from which a computer can read. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium and prior art-recognized equivalents and successor media, in which the software implementations of the present disclosure are stored.
[0016] The terms “determine”, “calculate”, and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.
[0017] The term “module” as used herein refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element. Also, while the disclosure is described in terms of exemplary embodiments, it should be appreciated that individual aspects of the disclosure can be separately claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present disclosure is described in conjunction with the appended figures:
[0019] FIG. 1 is a block diagram of a communication system in accordance with embodiments of the present disclosure;
[0020] FIG. 2 is a block diagram depicting a message exchange in accordance with embodiments of the present disclosure; and
[0021] FIG. 3 is a flow diagram depicting a communication method in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
[0022] The ensuing description provides embodiments only, and is not intended to limit the scope, applicability, or configuration of the claims. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing the embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the appended claims.
[0023] FIG. 1 shows an illustrative embodiment of a communication system 100 in accordance with at least some embodiments of the present disclosure. The communication system 100 may be a distributed system and, in some embodiments, comprises one or more communication networks 104 connecting one or more different communicating entities (e.g., enterprises, organizations, groups, homes, businesses, schools, corporations, individuals, families, subsets thereof, etc.) to a communication broker 124 . In some embodiments, the communication broker 124 acts as a centralized broker that has established trusted relationships with each of the different communicating entities. These trusted relationships may have been established personally, via snail mail, or via communications over the communication networks 104 . The trusted relationship is established vis-à-vis the sharing of authentication information from the communicating entity to the communication broker 124 and/or the sharing of contact information from the communicating entity to the communication broker 124 .
[0024] One advantage of using the centralized communication broker 124 is that the communicating entities only have to establish a single trusted relationship with the communication broker 124 to enable trusted and secure communications with other communicating entities. In particular, one communicating entity is relieved from the need to re-establish a trusted relationship with each communicating entity every time a secure communication with that communicating entity is desired. Rather, each communicating entity can rely on information provided from the communication broker 124 (with whom a trusted relationship has already been established) for establishing a secure communication session with any other communicating entity.
[0025] As can be seen in FIG. 1 , a communicating entity may be separated from the broader communication network 104 via an entity boundary 108 a, 108 b. Specifically, a first communicating entity may separate itself from the communication network 104 via a first entity boundary 108 a. The first communicating entity may have one or more first entity network boundary devices 112 a that help establish the boundary 108 a. Behind the network boundary device(s) 112 a may reside one or multiple first entity communication devices 116 a that are capable of being operated by one or more first entity users 120 a.
[0026] A second communicating entity may have similar components to the first communicating entity. For example, the second communicating entity may have one or more second entity network boundary devices 112 b that help establish a second entity boundary 108 b. Behind the network boundary device(s) 112 b may reside one or multiple second entity communication devices 116 b that are capable of being operated by one or more second entity users 120 b.
[0027] In accordance with at least some embodiments of the present disclosure, the communication network 104 may comprise any type of known communication medium or collection of communication media and may use any type of protocols to transport messages between endpoints. In particular, the communication network 104 may support synchronous, asynchronous, real-time, near-real-time, and any other type of electronic communications between two or more communication devices (e.g., 116 a, 116 b ) and/or between communication devices and servers.
[0028] The communication network 104 may include wired and/or wireless communication technologies. The Internet is an example of the communication network 104 that constitutes an Internet Protocol (IP) network consisting of many computers, computing networks, and other communication devices located all over the world, which are connected through many telephone systems and other means. Other examples of the communication network 104 include, without limitation, a Local Area Network (LAN), a Wide Area Network (WAN), a Session Initiation Protocol (SIP) network, a cellular network, and any other type of packet-switched and/or circuit-switched network known in the art. In addition, it can be appreciated that the communication network 104 need not be limited to any one network type, and instead may be comprised of a number of different networks and/or network types.
[0029] The communication devices 116 a, 116 b may correspond to any collection of components that enable users 120 a, 120 b to exchange media (e.g., voice, video, etc.), data (e.g., emails, Short Message Service (SMS) messages, Multimedia Message Service (MMS) messages, files, presentations, documents, etc. with one another's communication devices over the communication network 104 . Non-limiting examples of suitable communication devices 116 a, 116 b include a personal computer, laptop, tablet, Personal Digital Assistant (PDA), cellular phone, smart phone, telephone, soft phone, thin client, virtual machine, or combinations thereof. In general each communication device 116 a, 116 b may be adapted to support video, audio, text, and/or data communications with other communication devices 116 a, 116 b. The type of medium used to establish a communication channel between communication devices 116 a, 116 b may depend upon the communication applications available on the communication device(s) 116 a, 116 b.
[0030] The network boundary devices 112 a, 112 b may correspond to one or multiple devices that are used to maintain security within the communicating entity, especially as the communication network 104 may correspond to an untrusted network that is not necessarily considered secure. The network boundary devices 112 a, 112 b may also comprise the capability of interconnecting the network of the communicating entity to the communication network(s) 104 as the network of the communicating entity may not use exactly the same protocols as the communication network(s) 104 . More specifically, the network boundary devices 112 a, 112 b may correspond to any type of network security and/or translating device known in the art. Examples of a network boundary device 112 a, 112 b include, without limitation, a Session Border Controller (SBC), a gateway, a Network Address Translation (NAT) device, a firewall, a router, or any other collection of hardware and/or software that performs one or more functions such as filtering, protocol translation/mapping, impedance matching, rate conversion, fault isolation, signal translation, etc. as necessary to provide interoperability and/or security between a communicating entity and the communication broker 124 .
[0031] The communication broker 124 may comprise one or more components that enable the communication broker 124 to establish and maintain trusted relationships with multiple different communicating entities as well as facilitate the creation of secure communication sessions between different communicating entities. Examples of the components that may be included in the communication broker 124 include, without limitation, an authentication module 128 , a session controller 136 , and a media shuffler 140 . Although these components are depicted as being separate components, it should be appreciated that the functionality described in connection with these components may be incorporated into a single module or, on the other hand, distributed into many more different modules or sub-modules that are running on the same or different hardware device (e.g., server, processor, processor core, etc.).
[0032] The authentication module 128 may comprise authentication information 132 that has been obtained by various different communicating entities over the course of time. Specifically, the authentication information 132 may include any type of information that can be used by one entity to authenticate (one-way or mutually) another entity. For example, the authentication information 132 may include one or more of a password, keyword, pass phrase, key or set of keys (e.g., public/private or private/private), hash value, data string, bit string, data mask, etc. Authentication information 132 may also include any information that can be used to initially establish a communication channel between entities for the purposes of authentication. In some embodiments, the authentication information 132 may include information that enables the communicating entities to establish a communication channel according to the DTLS protocol. Examples of this type of data that may be included in the authentication information include, without limitation, addressing information such as one or more IP addresses, subnet identifier, domain name, port number, etc.
[0033] The authentication module 128 may be configured to receive authentication information 132 from communicating entities after a trusted relationship has been established between the communicating entity and the communication broker 124 as well as share the authentication information 132 with other communicating entities when a communication session has been requested by one communicating entity for another communicating entity (or multiple communicating entities).
[0034] The session controller 136 may comprise one or more modules that enable the communication broker 124 to establish a communication session between different communicating entities. In particular, the session controller 136 may comprise one or more of a SIP proxy, Back-to-Back User Agent (B2BUA), or the like that is capable of establishing a communication session between the communicating entities as well as maintaining a control dialog signaling for part or all of the duration of the communication session.
[0035] The media shuffler 140 , on the other hand, may comprise the capability to move a media stream from the communication broker 124 out of the communication broker 124 such that resources of the broker 124 (e.g., ports, sockets, memory, processors, etc.) are not consumed for the entire duration of the communication session between the communicating entities. However, the session controller 136 may stay in the signaling path between the communicating entities during some or all of the communication session. This enables the communication broker 124 to keep apprised of the status of the communication session, share pertinent information with the communicating entities and specifically the users 120 a, 120 b, all without requiring the communication broker 124 to provide the resources needed to carry the media between the communicating entities.
[0036] In some embodiments, the communication broker 124 may be owned and operated by one communicating entity, which means that the communication broker 124 does not necessarily have to be separated from all communicating entities by an entity boundary 108 a, 108 b. Rather, the communication broker 124 may be configured to be within one entity boundary (e.g., the first entity boundary 108 a ), which likely means that the first entity owns and/or operates the communication broker 124 .
[0037] It should be appreciated that while FIG. 1 only depicts the communication broker 124 being connected to two communicating entities, embodiments of the present disclosure are not so limited. Rather, embodiments described herein can be applied to any system having any number of communicating entities (e.g., three, four, five, . . . , one hundred, . . . , one thousand, etc.). The usefulness of the communicating broker 124 is that it affords many different communicating entities the ability to have secure communication sessions without having to establish trusted relationships (e.g., perform a complicated key exchange) with a large number of different communicating entities.
[0038] With reference now to FIGS. 2 and 3 , one example of a communication method that may be executed in accordance with embodiments of the present disclosure will be described. Specifically, FIG. 2 depicts the message flows that may occur in response to performing some or all of the steps depicted in FIG. 3 .
[0039] Although the devices of FIG. 2 are depicted as being physically separate, it should be appreciated that one of more of the components may be included in a common server. For instance, two or more of the universe policy application 204 , the communication server 208 , universe federation gateway 212 , and broker 124 may be included on a common server.
[0040] A communication method may be initiated when the communication broker 124 receives a request from a first communicating entity (e.g., Enterprise 1) to communicate with a second communicating entity (e.g., Enterprise 2) (step 304 ). The request received at the communication broker 124 may be originated by a single first entity communication device 116 a or multiple first entity communication devices. Furthermore, as can be seen in FIG. 2 , multiple messages may be transmitted before the communication broker 124 receives the request. As a non-limiting example, a SIP INVITE message (message A) may be transmitted from the first entity communication device 116 a to a communication server 208 in the first entity communication network (e.g., behind the first entity network boundary device 112 a ). This INVITE message may include information identifying the first entity user 120 a that is originating the request (e.g., From: Alice@A.com) as well as information identifying the second entity user 12 b that is the target of the request (e.g., To: Bob@B.com).
[0041] The communication server 208 may comprise functionality to analyze the information contained in the INVITE message and determine that the INVITE is directed toward a foreign domain (e.g., the second communicating entity). This determination may be made by analyzing the Request URI of the INVITE message. Upon determining that the INVITE message is directed toward a foreign domain, the communication server 208 may invoke a universe policy application 204 by sending it a request (message B) to continue with transmitting the INVITE message beyond the first entity boundary 108 a. The universe policy application 204 may respond to the communication server 208 with an Allow/Deny (message C).
[0042] Assuming that the universe policy application 204 transmits an Allow message to the communication server 208 , the communication server 208 continues by sending a DNS lookup message (messages D1 and D2) to the broker 124 via the universe federation gateway 212 . As can be appreciated, the universe federation gateway 212 may correspond to one example of a first entity network boundary device 112 a. The DNS lookup message receive at the communication broker 124 may correspond to the request referenced in step 304 of FIG. 3 . The response may alternatively, or in addition, correspond to some later message received at the communication broker 124 from the first communicating entity.
[0043] In response to receiving the DNS lookup message, the authentication module 128 and/or session controller 136 of the communication broker 124 may generate a response to the communication server 208 (message E) in the form of a DNSSEC/DNS resolution response.
[0044] The method continues with the communication broker 124 providing authentication information and connection information (e.g., authentication information 132 ) about the second communicating entity to the first communicating entity and vice versa (steps 308 , 312 , 316 , and 320 ). This information may be provided to the communicating entities in one or multiple steps depending upon the protocol employed by the communication broker 124 . In some embodiments, the communication broker 124 utilizes the DTLS protocol to enable the communicating entities to connect with one another and mutually authenticate with one another.
[0045] As can be seen in FIG. 2 , the mutual authentication between the communicating entities may occur with an exchange of messages between the communication server 208 , gateway 212 , broker 124 , and foreign domain 216 . Specifically, the communication server 208 may forward the INVITE message (message F) to the gateway 212 , where the INVITE message still identifies the intended recipient of the message (e.g., Bob@B.com). The gateway 212 and broker 124 may exchange one or more messages (message exchange G) to perform a mutual-TLS authentication as well as provide the INVITE message to the broker 124 . Similarly, the foreign domain 216 and broker 124 may exchange one or more messages (message exchange H) to perform a mutual-TLS authentication as well as provide the INVITE message from the broker 124 to the foreign domain 216 .
[0046] Upon completing this message exchange and after performing the mutual TLS exchange, the foreign domain 216 generates and sends a 200 OK message back to the communication server 208 (via messages I1, I2, and I3). Thereafter, the first communicating entity may authenticate the second communicating entity and vice versa (step 324 ). In some embodiments, the communicating entities use the authentication information that was previously provided by the broker 124 to authenticate the other communicating entity. As an example, the gateway 212 may transmit a SIP TLS message (message J) to the communication server 208 . The contents of the SIP TLS message may include SDP information that identifies the address of the foreign domain 216 (or more specifically the second entity network boundary device 116 b ) as well as the credential or fingerprint to use to authenticate the second communicating entity's network boundary device 112 b. The SIP TLS message and its contents may be protected in accordance with RFC 4474, the entire contents of which are hereby incorporated herein by reference. Moreover, the SIP TLS message may identify the first communicating entity as the client under the protocol.
[0047] At the same time, before, or after message J is transmitted to the communication server 208 , the broker 124 may also transmit a similar SIP TLS message (message K) to the foreign domain 216 and specifically to the second entity network boundary device 112 b. The contents of this SIP TLS message may include SDP information that identifies the address of the first enterprise network boundary device 112 a as well as the credential or fingerprint to use to authenticate the first communicating entity's network boundary device 112 a. The SIP TLS message and its contents may be protected in accordance with RFC 4474. Moreover, the SIP TLS message may identify the second communicating entity as the server under the protocol.
[0048] After the communicating entities have mutually authenticated one another, the method continues with the communication server 208 of the first communicating entity transmitting keying material or other parameters (message L) that can be used to establish an SRTP media stream between the communicating entities. This may be facilitated by the session controller 136 , which is still coordinating the establishment of the communication session between the entities. After the keying material has been shared from the first communicating entity to the second communicating entity, then a SRTP media stream may be established directly between the communicating entities (step 332 ). In some embodiments, the media shuffler 140 enables the shuffling of the media stream away from the communication broker 124 , but the signaling path between the communicating entities is still maintained through the broker 124 (step 336 ). The media path and corresponding signaling can be maintained until the call is terminated (e.g., due to one or both of the communication devices 116 a, 116 b hanging up or going back on-hook.
[0049] In the foregoing description, for the purposes of illustration, methods were described in a particular order. It should be appreciated that in alternate embodiments, the methods may be performed in a different order than that described. It should also be appreciated that the methods described above may be performed by hardware components or may be embodied in sequences of machine-executable instructions, which may be used to cause a machine, such as a general-purpose or special-purpose processor (GPU or CPU) or logic circuits programmed with the instructions to perform the methods (FPGA). These machine-executable instructions may be stored on one or more machine readable mediums, such as CD-ROMs or other type of optical disks, floppy diskettes, ROMs, RAMs, EPROMs, EEPROMs, magnetic or optical cards, flash memory, or other types of machine-readable mediums suitable for storing electronic instructions. Alternatively, the methods may be performed by a combination of hardware and software.
[0050] Specific details were given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
[0051] Also, it is noted that the embodiments were described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
[0052] Furthermore, embodiments may be implemented by hardware, software, firmware, middleware, microcode, hardware description languages, or any combination thereof. When implemented in software, firmware, middleware or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine readable medium such as storage medium. A processor(s) may perform the necessary tasks. A code segment may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
[0053] While illustrative embodiments of the disclosure have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art. | A communication broker and methods of administering the same are provided. The communication broker is adapted to direct various enterprises to set up a media channel directly therebetween while remaining in the control signaling path for the communication session. The broker may enable the enterprises to use standard authentication techniques and the Datagram Transport Layer Security (DTLS) protocol to establish the media channel. | 7 |
FIELD
[0001] This relates to a method and apparatus for supporting cables within coiled tubing.
BACKGROUND
[0002] Coiled tubing has become a more common element for use in downhole operations, and may be used to house cables, such as, supply lines, capillary tubing, and the like, U.S. Pat. No. 6,352,113 (Neuroth), entitled “Method and apparatus to remove coiled tubing deployed equipment in high sand applications” and U.S. Pat. No. 6,143,988 (Neuroth et al.), entitled “Coiled tubing supported electrical cable having indentations” each describe different supports used to support a cable within the coiled tubing.
SUMMARY
[0003] According to an aspect, there is provided a method of hanging a cable within a coiled tubing string. The cable has a first end and a second end. The method comprises the steps of providing a coiled tubing string having a length required within a well having a wellhead, the coiled tubing having a wellhead attachment section and a downhole end spaced from the wellhead attachment section; determining a length of a cable required within the coiled tubing string, the cable comprising an elongate structural component that extends along the length of the cable, the structural component being sufficient to independently support the weight of the cable; cutting the coiled tubing string into first and second sections and installing a hanger sub in the coiled tubing string between the first and second sections toward the wellhead attachment section relative to the downhole end, the hanger sub comprising an inner shoulder that extends radially into the hanger sub and defines an opening; attaching an outer shoulder to the elongate structural component of the cable and inserting the cable into the coiled tubing string until the outer shoulder engages the inner shoulder of the hanger sub such that the cable is hanging within the coiled tubing string below the inner shoulder; and installing the coiled tubing string in a wellhead such that the wellhead attachment section is adjacent to the wellhead and the hanger sub is below the wellhead.
[0004] According to another aspect, the hanger sub may be attached to the coiled tubing such that the outer profile is in line with the outer profile of the coiled tubing
[0005] According to another aspect, the cable may comprise a supply line.
[0006] According to another aspect, the method may further comprise the step of attaching the second end of the cable to a downhole tool. The downhole tool may be an electric submersible pump.
[0007] According to another aspect, the structural component may comprise a metal capillary tube.
[0008] According to another aspect, the cable may comprise a bundle of supply lines. The hanger sub may comprise two or more apertures, at least one aperture comprising the inner shoulder that engages the elongate structural component, at least a portion of the bundle of supply lines passing through a separate aperture, the elongate structural component structurally engaging the supply lines below the hanger sub. The elongate structural component may comprise a metal capillary tube in the bundle of supply lines.
[0009] According to another aspect, the cable may comprise a resistive heating element.
[0010] According to another aspect, the hanger sub in the coiled tubing string may be between 1 and 50 meters below the wellhead when installed, or between 5 m and 25 m below the wellhead when installed.
[0011] According to another aspect, the hanger sub in the coiled tubing string may be positioned below the wellhead end of the coiled tubing string at a depth of between 1% and 5% of the wellbore depth.
[0012] According to another aspect, at least one of the shoulder of the hanger sub and the shoulder on the cable may be slotted to prevent rotation of the cable.
[0013] According to another aspect, the weight of the cable may be supported solely by the hanger sub.
[0014] According to an aspect, there may be provided, in combination, a cable and a length of coiled tubing string. The cable has a first end and a second end and comprises a structural component along the length of the cable. The structural component is sufficient to support the weight of the cable. The length of coiled tubing string has a wellhead end and a downhole end. The coiled tubing string has a first section and a second section connected by a hanger sub. The hanger sub comprises an inner shoulder that extends radially into the hanger sub and defines an opening. The cable has an outer shoulder capable of engaging the inner shoulder of the hanger sub, such that, when installed through a wellhead, the hanger sub is positioned below the wellhead.
[0015] According to another aspect, the outer profile of the hanger sub may be in line with the outer profile of the coiled tubing
[0016] According to another aspect, the cable may comprise a supply line.
[0017] According to another aspect, the second end of the cable may have a downhole tool attached. The downhole tool may be an electric submersible pump.
[0018] According to another aspect, the structural component may comprise a metal capillary tube.
[0019] According to another aspect, the cable may comprise a bundle of supply lines. The hanger sub may comprises two or more apertures, at least one aperture comprising the inner shoulder that engages the elongate structural component, at least a portion of the bundle of supply lines passing through a separate aperture, the elongate structural component structurally engaging the supply lines below the hanger sub. At least one supply line may comprise a metal capillary tube, the metal capillary tube providing structural support to the supply lines.
[0020] According to another aspect, the cable may comprise a resistive heating element.
[0021] According to another aspect, the hanger sub may be installed, at a distance of between 1 and 50 meters from the wellhead end, or at a distance of between 5 and 25 m from the wellhead end.
[0022] According to another aspect, the hanger sub in the coiled tubing string may be positioned below the wellhead end of the coiled tubing string at a depth of between 1% and 5% of the well bore depth.
[0023] According to another aspect, at least one of the shoulder of the hanger sub and the shoulder on the cable may be slotted to prevent rotation of the cable.
[0024] According to another aspect, the weight of the cable may be supported solely by the hanger sub when installed in the wellhead.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] These and other features will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to be in any way limiting, wherein:
[0026] FIG. 1 is a side elevation view in section of a supply line hanging in a coiled tubing string.
[0027] FIG. 2 is a top view of a hanger sub.
[0028] FIG. 3 is a top view of a hanger sub in a particular embodiment.
[0029] FIG. 4 is a side elevation view of a hanger sub.
[0030] FIG. 5 is a side elevation view of an apparatus for servicing an electric submersible pump.
[0031] FIG. 6 is a side elevation view of a well completion with an electric submersible pump connected to surface by a coiled tubing string and elongate supply lines within the coiled tubing string.
DETAILED DESCRIPTION
[0032] An apparatus and method of positioning a cable within a coiled tubing string will be described with reference to FIGS. 1-6 in the context of an electric submersible pump in a well with a positive well head pressure. It will be understood that the support described below may also be used in other situations as well.
[0033] Referring to FIG. 6 , well 12 , which may be a pressurized well, includes a casing 14 and a wellhead 16 mounted to casing 14 . Wellhead 16 has a sealable injection port 18 , and production ports 20 . Referring to FIG. 5 , injection port 18 may be sealed by a blow out preventer (BOP) 32 as shown, or it may also be sealed by a valve, a plug, etc., which may be above or below the actual port 18 . Referring again to FIG. 6 , the number of production ports 20 may vary depending upon the design of wellhead 16 . Production tubing 22 is positioned in casing 14 and is connected to wellhead 16 . Production fluids that are pumped upward by electric submersible pump 10 flow through production tubing 22 and out production ports 20 of wellhead 16 . Electric submersible pump 10 is carried by a coded tubing string 24 at a downhole end 26 of coiled tubing string 24 , and is sized such that it is able to be run through production tubing 22 . Cables, which may include a metal capillary tube 28 and other supply lines 29 as shown, are run through and enclosed within coiled tubing string 24 and connect to electric submersible pump 10 . Metal capillary tube 28 is preferably used to supply oil, while other supply lines 29 may be used for power, communication lines, control lines, instrumentation lines, resistive heating elements, and the like. The choice of cable may be such that the cable is structurally self-supporting. Alternatively, metal capillary tube 28 provides structural support to supply lines 29 . A pump-receiving housing 30 , shown in FIG. 5 , is located above injection port 18 of wellhead 16 . The height of pump receiving housing 30 will depend upon the size of electric submersible pump 10 . Pump-receiving housing 30 is designed such that is may be sealed to the atmosphere when injection port 18 is open, and openable to the atmosphere when injection port 18 is sealed. In other words, housing 30 works with injection port 18 to ensure that well 12 is always sealed when it is pressurized. Referring to FIG. 5 , a BOP 32 is located above wellhead 16 and below pump-receiving housing 30 . Coiled tubing injector 34 is located above pump-receiving housing 30 and, referring to FIG. 6 , is used to control the position of coiled tubing string 24 and electric submersible pump 10 in well 12 .
[0034] Referring to FIG. 1 , metal capillary tube 28 provides structural support to supply lines 29 . As shown, this is done by attaching supply lines 29 to capillary tube 28 using clamps 31 , although it may also be done in other ways. For example, supply lines 29 and capillary tube 28 may be encapsulated together. Furthermore, supply lines 29 and capillary tube 28 may be any self-supporting cable that acts as a structural component and that may be used in downhole applications.
[0035] As shown, supply lines 29 generally require structural support as the lengths of tube 28 and lines 29 may be long enough to overcome the inherent strength of lines 29 and stretch or break. Once supply lines 29 are supported by capillary tube 28 they become self-supporting. Capillary tube 28 and supply lines 29 are mounted within and supported by coiled tubing string 24 . This is done by providing coiled tubing string 24 with a hanger sub 102 that has a shoulder 104 that engages a corresponding shoulder 106 carried by capillary tube 28 . Hanger sub 102 is preferably close to surface 108 , such as between 1 meter and 50 meters below surface, such that the majority of the length of capillary tube 28 is below hanger sub 102 and coiled tubing string 24 and there will not be movement at the surface where there is required an anchor point, Alternatively, capillary tube 28 may be mounted at a position that is based on a percentage of the depth of the wellbore, such as between 1% and 5%, Hanger sub 102 is preferably a single body but may be a two-piece that can be placed around supply lines 29 . As shown, the hanger sub shoulder is integrally formed with the hanger sub. The hanger sub is welded or otherwise attached to the coiled tubing such that the outer profile is in line with the outer profile of the coiled tubing. This ensures that the coiled tubing does not have an external upset or any increased outer diameter, which allows for ease of transport and installation. The hanger sub is attached by welding or another method in such a way that it does not substantially degrade the mechanical properties of the coiled tubing and has properties that are within the specifications for the coiled tubing string as a whole. This is particularly useful in thermal applications. Where the properties including resistance to corrosion are maintained within the specifications required for the coiled tubing.
[0036] Referring to FIGS. 2 and 4 , hanger sub 102 has an opening 110 through which the cable will pass. The shoulder 106 attached to the cable will engage hanger sub shoulder 104 , positioning the cable within the hanger sub 102 .
[0037] Referring to FIG. 3 , in a particular embodiment, hanger sub shoulder 104 may have an additional opening 112 that provides a passage for an additional support cable if needed. In this embodiment the cable may have a support line such as a capillary support tube, metal wire, or rod, attached to the cable to provide structural support below the hanger sub. The support line may carry the shoulder 106 which is positioned above opening 112 , shoulder 106 engaging with hanger sub shoulder 104 at opening 112 .
[0038] Referring to FIG. 4 , hanger sub 102 is shown from a side elevation.
[0039] The description above assumes a situation where both power or communication and fluid supply are connected to a downhole tool. However, this may change depending on the circumstances. For example, rather than a bundle of supply lines 28 and 29 , in some circumstances there may only be a metal capillary tube 28 , or more than one capillary tube 28 . In other circumstances, there may not be a capillary tube 28 . While a metal capillary tube 28 is useful for providing structural support, other structural members may also be provided if fluid is not required downhole, such as a metal wire or rod that are less expensive than capillary tube 28 .
[0040] When one hanger sub 102 is provided, capillary tube 28 may be run in to coiled tubing string 24 without any other hindrance, and will be properly positioned once it is correctly inserted without taking any additional steps in the process. By knowing the length of coiled tubing string 24 and the length of capillary tube 28 , hanger sub 102 and outer shoulder 106 may be installed to have each end at the correct position, such as to attached to an electric submersible pump 10 as shown in FIG. 6 , or any other downhole tool that may be run on a coiled tubing string.
[0041] The above structure may be used when installing or removing an electric submersible pump 10 without having to cool well 12 . In the depicted example, in order to insert electric submersible pump 10 into a well with a positive well head pressure, injection port 18 is first sealed by closing BOP 32 . Pump-receiving housing 30 contains electric submersible pump (ESP) 10 , which is then connected to coiled tubing string 24 . Pump receiving housing 30 is then mounted to the BOP 32 . Pump-receiving housing 30 is then closed and sealed to atmosphere and BOP 32 is opened to allow electric submersible pump 10 to be inserted through injection port 18 in wellhead 16 and into well 12 by operating coiled tubing injector 34 . In order to remove electric submersible pump 10 from pressurized well 10 , the process is reversed, with coiled tubing injector 34 lifting electric submersible pump 10 through wellhead 16 and into housing 30 . BOP 32 is then closed and sealed, and housing 30 is either opened or removed from BOP 32 to provide access to electric submersible pump 10 . Electric submersible pump 10 may then be serviced or replaced, as necessary.
[0042] As depicted, electric submersible pump 10 is preferably an inverted electric submersible pump, and is run off a 1¼″-3½″ coiled tubing string 24 that contains the instrumentation lines. Other sizes may also be used, depending On the preferences of the user and the requirements of the well. When compared with traditional electric submersible pumps, electric submersible pump 10 lacks the seal section, motor pothead and wellhead feedthrough. As shown, electric submersible pump 10 includes a power head 27 , motor section 38 , thrust chamber 40 , one or more seal rings 42 and electric submersible pump section 44 . Thrust chamber 40 includes two mechanical seals with a check valve (not shown), and replaces the conventional seal/protector section that separates pump section 44 and motor section 38 . The check valve in thrust chamber 40 allows the lubricating fluid supplied by capillary tube 28 to exit thrust chamber 40 and comingle with, for example, produced fluids from the well with the pump discharge from outlet ports 50 . Seal rings 42 seal against a pressure sealing seat 46 that is carried by production tubing 22 , to provide seal between inlet ports 48 and outlet ports 50 . Inlet ports 48 are in communication with downhole fluids to be pumped to surface via outlet ports 50 , which are positioned within production tubing 22 .
[0043] In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.
[0044] The following claims are to be understood to include what is specifically illustrated and described, above, what is conceptually equivalent, and what can be obviously substituted. Those skilled in the art will appreciate that various adaptations and modifications of the described embodiments can be configured without departing from the scope of the claims. The illustrated embodiments have been set forth only as examples and should not be taken as limiting the invention. it is to be understood that, within the scope of the following claims, the invention may be practiced other than as specifically illustrated and described. | A method of hanging a cable within a coiled tubing string includes the steps of determining a length of coiled tubing required within a well having a wellhead; determining a length of a cable required within the coiled tubing, the cable having a structural component along the length of the cable sufficient to support the weight of the cable; cutting the tubing string and installing a hanger sub in the coiled tubing string toward, the wellhead attachment section relative to the downhole end, the hanger sub comprising an inner shoulder that extends radially into the hanger sub and defines an opening; and attaching an outer shoulder to the cable and inserting the cable into the coiled tubing string until the outer shoulder of the cable engages the inner shoulder of the hanger sub such that the inner shoulder positions the cable below the outer shoulder. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a supporting floor for the core of a nuclear reactor. More particularly, the supporting floor comprises a plurality of graphite blocks arranged in vertical columns. The nuclear reactor, preferably a gas cooled nuclear reactor, comprises a reactor core in the form of a pile of spherical fuel elements surrounded by a cylindrical side reflector and a thermal side shield arranged at a distance from the side reflector. The vertical columns of the supporting floor are provided with bores in the longitudinal direction and rest on the base of the nuclear reactor itself.
2. Background of the Prior Art
West German Offenlegungsschrift No. 1 956 226 discloses a gas cooled nuclear reactor having a core of graphite blocks arranged in vertical columns. The core is supported on the floor of the reactor pressure vessel by means of several layers of a refractory material, for example, graphite. Each column of the core is supported by its own supporting column. The supporting columns consist of several graphite blocks stacked on top of each other. Access for the cooling gas to the core is provided by means of channels formed into the graphite blocks of the support layers and connected with gas conduits in the core and with a gas space outside the core. The entire structure of supporting columns is surrounded by packing blocks arranged between the structure and the lining of the pressure vessel.
West German Published Application No. 1 261 606 shows a nuclear reactor with a radiation reflector inserted between the thermal shield and the core of the reactor. The reflector consists of a lateral reflector enclosing a cylindrical cavity and a lower reflector serving as the supporting floor. The lower reflector is formed by two layers of ashlar shaped graphite blocks differing in their longitudinal direction from one layer to the other. In each of the layers the blocks arranged around a central opening are maintained together and locked against each other by means of wedges. The lateral reflector, which consists of graphite blocks stacked in layers, one upon the other, is supported by the thermal side shield. A plurality of elastic structural parts acting in the radial direction provides this support.
The prior art further includes a supporting floor for a pebble bed reactor consisting of a gas permeable supporting layer of spheres of high temperature resistant material and a support structure designed for the weight of the supporting pebble bed layer and the fuel elements. The fuel elements are piled directly onto the supporting pebble layer. A layer of high temperature resistant tiles is arranged between the support structure and the supporting pebble layer.
In another pebble bed reactor, the THTR-300 MWe, the support floor for the pile of fuel pellets comprises a plurality of hexagonal graphite blocks arranged in freely movable columns and containing axial bores for the cooling gas. Each column formed by the graphite blocks is supported individually by a circular column. The circular column is built into a floor of graphite plates. The expansion gaps obtained by a reduction of the nominal dimensions of the graphite blocks permit the unimpaired thermal expansion of the elements of the support floor without exceeding the overall dimensions. Under certain non-stationary operating conditions, or in the case of failures, respectively, these gaps may add up and relatively large individual gaps may be formed. However, in view of the dimensions of the THTR-300 MWe, the restoring forces required to close the gaps are of negligible importance.
A supporting structure for a pebble bed reactor of greater capacity is known from West German Offenlegungsschrift No. 27 18 493. This support structure consists of several layers of prismatic graphite blocks arranged over each other and built up as a closed unit without expansion gaps. The blocks of one layer are keyed into the blocks of the adjacent layer. The preferred hexagonal graphite blocks display widths across their flats in the upper layers that are different from those in the bottom layer, which is formed of a plurality of supporting units. Each supporting unit is resting in its central area of a circular column and is composed of a number of carrier segments. The support structure represents a stable and rigid plate. Because of the keying of the prismatic blocks, no restoring force is required. However, in the case of this known structure, certain specific measures must be taken to counter the deformations occurring in the bottom layers of the nuclear reactor or in the bottom of the pressure vessel, respectively.
SUMMARY OF THE INVENTION
The present invention is an improvement of the abovedescribed state of the art and is directed specifically to providing a support floor for a nuclear reactor having spherical fuel elements. The structure of the present invention avoids the reactive forces and the excessive thermal stresses often found in the known reactors and generated as the result of the existance of radial temperature profiles. Adjustments without strain to the deformations of the bottom of the pressure vessel are also possible in the structure of this type.
These and other objects are attained according to the invention by placing the vertical columns as independent individual columns, directly adjacent to each other, without expansion gaps and by maintaining the columns together in the horizontal direction by means for retaining the columns in their original relative horizontal position. This means is arranged in the annular space between the lower part of the side reflector and the thermal side shield. The means is preferably a plurality of restoring elements such as spring supports or support struts.
The supporting floor arrangement of the invention performs all of the functions required of it. For example, it transmits the vertical forces of the pile of fuel elements downward, it passes the horizontal forces by way of restoring elements to the thermal side shield, it also performs the task of shielding and of conducting the hot gas from the reactor core to the hot gas collector space.
Because the supporting floor has been resolved into a plurality of independent, individual columns, the differential thermal expansions of the columns are not restricted. Stationary and non-stationary temperature fields, therefore, do not lead to the generation of reactive forces or substantial thermal stresses. The support floor is not sensitive relative to manufacturing and assembly tolerances and adapts without strain to the deformations of the bottom of the pressure vessel.
Vibrations of the individual columns of the support floor are practically excluded, because the support floor of a pebble bed reactor customarily has an inclined surface (for the removal of the spherical fuel elements at least one pebble outlet tube must be provided with a conical tube inlet located within the support floor) and the columns are maintained together by means of elements that retain, restore or reset the columns under stress.
The vertical columns of the support floor according to the invention preferably have a hexagonal cross section. The columns are placed adjacent to each other so that they are generally in contact with each other. (Of course some gaps due to manufacturing conditions are possible and tolerable).
Advantageously, an additional circular column may be provided for each hexagonal column. The circular column rests on the bottom layers of the nuclear reactor while the hexagonal column rests on the circular column. The circular columns conveniently have diameters smaller than the width of the bottom surface of the hexagonal columns. The free space created in this manner around the circular columns forms a hot gas collector space of the nuclear reactor. The circular columns acting as linked supports for the hexagonal columns, may be built into the bottom layers of the nuclear reactor.
In high capacity nuclear reactors having large reactor cores, the retaining means is comprised of a plurality of restoring elements. These are advantageously designed in the form of spring supports. By such means, the vertical columns are maintained together in the radial direction so that no gaps or only acceptably small gaps, exist between the vertical columns. Preferably, the spring supports are arranged so that the gaps appearing between the vertical columns after extended operating periods or following a non-stationary operation are limited to a predetermined maximum size. In the process, the horizontal forces of the pile of fuel elements must be safely transferred to the thermal side shield. At the same time, the differential thermal expansions of the support floor and the thermal side shield must also be possible.
In nuclear reactors with lesser capacities, support struts may be used as the restoring elements; they must be arranged with clearance between the support floor and the thermal side shield. The differential radial thermal expansions of the support floor and the thermal shield are taken into account by that the maximally possible differential thermal expansion of the above-mentioned two structural parts are set at the support struts as clearances.
When the support floor according to the invention is used in nuclear reactors having their reactivities affected by means of absorber balls with substantially smaller diameters than those of the spherical fuel elements, spring supports are utilized (independently of the size of the core structure) as the restoring elements. The restoring force is designed so that the dimensions of the gaps being formed between the vertical columns remains smaller than the diameter of the absorber balls, even toward the end of the operation of the nuclear reactor.
Gaps are created not only by the temperature load during an extended operating period, but occur also under certain operating conditions. Thus, gaps are dependent on the operation and temperature conditions. The restoring forces of the spring supports have the function of suppressing the gaps between the vertical columns or at least to limit their size, in order to prevent the penetration of the absorber balls into any gaps that form and thus causing the straining of the assembly.
It may be appropriate to provide a number of gaps in the side reflector. This will prevent the side reflector from becoming unable to transmit forces to the support floor due to a pressure ring support effect, under certain conditions.
According to an advantageous further embodiment of the invention, the bores for the cooling gas in the vertical columns are provided in relation to number, diameter and distance so that in the individual vertical columns either none or only very slight non-stationary thermal stresses are generated. Numerous individual bores may be arranged to pass through each vertical column in the longitudinal direction such that the temperatures prevailing in the support floor arrangement adapt uniformly to temperature transients, whenever such occurs.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, two support floors for a pebble bed reactor are schematically represented as examples of certain embodiments of the invention.
In the Drawings:
FIG. 1 shows a vertical section through the general structure of a support floor of the present invention;
FIG. 2 represents an individual column of the support floor of FIG. 1;
FIG. 3 shows in detail a vertical cross section through the support floor of an embodiment of the invention, and
FIG. 4 represents a top view of the support floor of another embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
FIG. 1 shows the core 1 of a gas cooled high temperature reactor formed by a pile of spherical fuel elements, surrounded by an annular side reflector 2. The side reflector is surrounded in turn by a thermal side shield 3, wherein an annular space 4 is provided between the two structural parts. Several pebble removal tubes (one such tube 16 is shown in FIG. 3) exit through the bottom of the pebble bed. Depending on the size of the nuclear reactor installation, the number of pebble removal tubes may vary between 1 and 7. A conical pebble inlet 17 shown in FIG. 3 is provided for each pebble removal tube, which is formed by a part of the support floor.
The portion of the support floor arrangement of the invention shown in FIG. 2 consists of a plurality of graphite blocks 6a, arranged in vertical columns 6. The vertical columns 6 have hexagonal cross sections shown in FIG. 4 and are equipped with numerous bores 7 extending in the longitudinal direction through which the cooling gas heated in the core 1 may exit from the core.
The structure shown in FIG. 2 illustrates a single column 6 with cooling gas bores 7. The cooling gas bores 7 are established with respect to number, diameter and distance so that no or only slight non-stationary thermal stresses may be generated in the individual vertical columns. The graphite blocks 6a located at different heights or in different layers may have different configurations with respect to the cooling gas bores 7. In the embodiments shown herein, the uppermost layer of the graphite blocks 6a has a greater number of cooling gas bores 7 than the other layers and a small gas collector space 8 is located at the upper end of the second layer from the top. This space is interconnected with the cooling gas bores in the uppermost and the second layer from the top.
The vertical columns 6 of the support floor 5 may be constructed of hexagonal graphite blocks having different widths across the flats in the individual layers.
As shown in FIGS. 1 and 2, each vertical column 6 resting on a circular column 9 is in turn supported on the bottom layers 10 of the high temperature reactor. The bottom layers 10 are supported by a floor plate 11. The diameter of the circular columns 9 is smaller than the flat width or end surface of the vertical columns 6. The free space between the circular columns 9 forms the hot gas collector space 12 of the high temperature reactor and is, therefore, interconnected with the cooling gas bores 7 in the graphite blocks 6a in such a manner that the gas freely flows therebetween.
Because the vertical columns 6 are placed adjacent to each other as independent single columns without expansion gaps, the support floor arrangement 5 as a whole is not sensitive to thermal stresses and is capable of adjusting without strain to deformations of the bottom layers 10 and the floor plate 11. In order to keep the size of the gaps between the columns within the design parameters under all manufacturing, operational and thermal conditions, retaining means 13 acting inwardly in the radial direction are arranged in the annular space 4 as indicated in FIG. 1 by arrows. The type and layout of the retaining means 13 is determined by the reactor capacity and the core dimensions of the high temperature reactor.
In FIG. 3, a support floor 5 for a high temperature reactor of small or intermediate capacity is shown. Identical structural elements are designated by the same reference symbols as in FIGS. 1 and 2. FIG. 3 shows that the side reflector consists of a plurality of stacked graphite blocks 2a and rests by means of roller bearings on the bottom of the reinforced concrete pressure vessel 15 surrounding the high temperature reactor. The restoring elements arranged between the thermal side shield 3 and the side reflector 2 consist of supporting struts 13a, provided with a clearance corresponding to the maximum possible differential radial thermal expansion of the support floor 5 and the thermal side shield 3. In the event that the reactor is designed to utilize absorber balls for the shutdown of the high temperature reactor, the restoring elements consist of spring supports in order to suppress or limit the gaps with respect to size.
The reactor core 1 has several pebble outlet tubes 16 passing through the support floor 5, each of them being provided with a conical pebble inlet 17. The surface of the support floor 5 is designed so as to form the said conical pebble inlets.
FIG. 4 exhibits another embodiment of the support floor 5 according to the invention, intended for a high capacity, high temperature reactor. A total of seven pebble outlet tubes 16 are provided under the reactor core 1, four of which are shown in the drawing. Toward the side reflector 2, the graphite blocks 6a of the vertical columns 6 have a different configuration in cross section. The shape of the cross sections are varied so that each individual graphite block 6a is radially restrained. FIG. 4 demonstrates the arrangement of the vertical columns 6 directly adjacent to each other.
As the restoring elements for this support floor, spring supports 13b are provided; they are arranged in the annular space 4 and hold the vertical columns 6 together in the radial direction. In order to prevent the development of a pressure ring support effect in the side reflector 2, the latter is provided with a series of gaps 18 between the individual graphite blocks 2a. The spring supports 13b are laid out that the gaps developing after an extended period of operation of the high temperature reactor between the vertical column 6, remain under a predetermined maximum size. If in the high temperature reactor absorber balls having diameters substantially smaller than those of the fuel elements are used to affect the reactivity of the reactor, the predetermined maximum size of the gaps is also given by the diameter of the absorber balls. | A supporting floor for the core of a nuclear reactor utilizes a plurality of independent support columns forming the floor of the reactor and resting on the bottom layers of the reactor. The support columns are surrounded by a side reflector which is in turn surrounded by a thermal side shield. Between the thermal side shield and the side reflector are disposed retaining means for maintaining the columns close together and preventing the formation of large gaps during operation. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to German Applicant No. 10 2015 212 916.0, filed Jul. 9, 2015, the contents of which are hereby incorporated herein in its entirety by reference.
TECHNOLOGICAL FIELD
[0002] The invention relates to a hob comprising a hob plate and comprising at least one heating device which is arranged beneath the hob plate.
BACKGROUND
[0003] By way of example, US 20130098351 A1 and EP 2642821 B1 disclose indicators or indicator lights on hobs, which indicators or indicator lights do not operate simply only with a lighting means such as, for example, an LED which is arranged in a visible position. Materials with extraordinary properties are used here.
BRIEF SUMMARY
[0004] The invention is based on the object of providing a hob of the kind cited in the introductory part with which problems of the prior art can be solved and it is possible, in particular, to provide an advantageous indicator light on a hob.
[0005] This object is achieved by a hob. Advantageous and preferred refinements of the invention are the subject matter of the further claims and will be explained in greater detail in the text which follows. The wording of the claims is incorporated in the content of the present application by express reference.
[0006] It is provided that the hob has a hob plate and at least one heating device which is arranged beneath the hob plate. The hob plate can advantageously be composed of hard glass or of glass ceramic, as is known per se. The hob plate can be largely transparent or of a reddish-brown color. The hob plate is advantageously designed such that it transmits light in a wavelength range which is visible to the human eye, even if this is only a low level of transmissivity. This wavelength range extends from approximately 380 nm to 780 nm. The level of transmissivity does not necessarily have to apply to the entire wavelength range which is visible to the human eye, but rather can also apply for narrow ranges or substantially individual colors. In the IR wavelength range, the hob plate can be transparent or have a transmission of more than 50%, advantageously more than 80% or even 90%. This is primarily advantageous when using radiant heating bodies or generally electrical resistance heaters which have very high temperatures and therefore a very strong IR radiation component.
[0007] The heating device operates electrically and preferably has an electrical resistance heater which is arranged on a support with thermal insulation. The resistance heater can firstly be a so-called strip-like resistance heater in the form of a radiant heater, as is known, for example, from U.S. Pat. No. 5,393,958 B1. Here, the electrical resistance heater, by way of its strip, is exposed to the atmosphere, wherein it is arranged partially on a support with a thermal insulation. This thermal insulation can advantageously be of flat or board-like or plate-like design, wherein the resistance heater or the resistance heating element rests on the thermal insulation, possibly in a partially embedded manner.
[0008] As an alternative, the heating device can have an electrical resistance heater in the form of a so-called tubular heating body, as is known, for example, from EP 2481259 B1. In this case, the actual resistance heating element is situated in a metal tube in a manner surrounded by insulating material, it being possible for the metal tube ultimately to be heated by the resistance heating element or even to be made to glow and then likewise operate as a radiant heater. In a further alternative, an electrical resistance heater can be a so-called halogen lamp, also known as a bright radiator, as can likewise be used for hobs. The alternative resistance heaters are also arranged on supports with thermal insulation in order to increase the amount of thermal radiation at the top to a cooking vessel which is placed above it on the hob plate or to improve the energy efficiency. Furthermore, heating of the hob at the bottom into an item of fitted furniture or the like should not be too excessive.
[0009] An IR-stimulable material which forms an indicator light or a lighting means is designed such that it can be excited by light in the IR wavelength range and then outputs light. Therefore, it can serve as an abovementioned indicator light or lighting means. This effect is a fluorescence and, respectively, these materials are also called anti-Stokes materials. Light in the IR wavelength range is always present during the heating operation owing to the abovementioned resistance heater and usually also for a short time after the heating operation while the resistance heater, for example after switch-off, is still hot enough or as long as it has not yet cooled to too great an extent. Owing to the use of the IR stimulable material, which can be material comprising quantum dots in particular, an indicator light or lighting means can be generated with colors other than with red to orange or orangey yellow as are emitted by customary glowing resistance heaters. IR-stimulable materials of this kind are also known from U.S. Pat. No. 4,806,772 A, the content of the document in respect of these materials also being incorporated in the content of the present application by express reference.
[0010] In this case, the IR-stimulable material is arranged on the resistance heater and/or on the thermal insulation and/or on the hob plate and/or on an additional support. The IR-stimulable material is advantageously located in the immediate region which is subjected to strong irradiation by thermal radiation by the heating device or the resistance heater. The arrangement of the IR-stimulable material on an additional support or the like, which additional support can be arranged on the heating device or primarily on the thermal insulation, may, however, mean expenditure on an additional part which is dispensed with when parts of the hob or the heating device which are present in any case are used.
[0011] This IR-stimulable material should be selected to be correspondingly temperature-stable, so that a long-term temperature stability for temperatures of greater than 1000° C. is provided. Primarily in the case of exposed electrical resistance heaters which visibly glow brightly during the heating operation, the temperatures should even be still higher, for example up to 1300° C. The abovementioned tubular heating bodies are generally not hotter than 1000° C., even when they begin to glow.
[0012] One advantage of the high temperature resistance or temperature stability of the materials, in addition to the use at high heating conductor temperatures, is also that this temperature resistance permit high-temperature production processes, such as enamelling, casting, sintering, stoving or the like for example.
[0013] The IR-stimulable material can generally be rare earth-doped. The IR-stimulable material can advantageously contain erbium or be doped with erbium. The erbium can particularly advantageously be ER 3+ . The IR-stimulable material is preferably material comprising so-called quantum dots or quantum rods. Materials of this kind, also called anti-Stokes materials, emit visible light when excited by IR-radiation or heat. Owing to the size of the constituent parts of the material, in particular of the quantum dots, the wavelength of the emitted light can be influenced within certain limits. For example, it is possible for a peak of the light emitted by the material comprising the quantum dots in the wavelength range of between 510 nm and 560 nm to be achieved by quantum dots from CAN, Hamburg, under the product name CANdots Series X Green. A further emission peak can be achieved in another wavelength range of between 640 nm and 690 nm.
[0014] The IR-stimulable material can be provided as an indicator light which can be identified from above through the hob plate, advantageously in the region or heating region of the at least one heating device. In one refinement of the invention, it is possible for the IR-stimulable material to be arranged at least partially directly above the heating device on the hob plate, preferably on the bottom face of the hob plate. Although it would be possible to apply the said IR-stimulable material to the top face of the hob plate, the mechanical loading during daily use when cooking over the long term is too high for the resistance of these IR-stimulable materials or of quantum dots. Therefore, it is considered to be advantageous when the IR-stimulable material is arranged on the bottom face of the hob plate or is applied to the bottom face of the hob plate. In this case, the IR-stimulable material is advantageously applied as a coating on the hob plate. However, at the same time, the IR-stimulable material should still be largely or even fully transmissive for IR thermal radiation of the resistance heating element to the outside.
[0015] In an alternative refinement of the invention, the IR-stimulable material can be an integral constituent part of the hob plate or can be admixed with the material of the hob plate. Therefore, the IR-stimulable material does not form a coating here, but rather is incorporated into the material of the hob plate. Furthermore, it is possible for the IR-stimulable material to be mixed into the material of the hob plate in such a way that certain shapes or symbols are formed, in particular adapted for the subsequent arrangement of the heating device on the hob. Therefore, complicated coating methods can be dispensed with.
[0016] In a further alternative refinement of the invention, the IR-stimulable material can be provided on the heating device, advantageously directly on the heating device. In this case, it can be provided, for example, directly on the abovementioned thermal insulation or on the abovementioned support since, as a result, the properties in respect of heat generation and thermal radiation at the resistance heater are lower. The temperature at an exposed resistance heater is also very high at the abovementioned temperatures of 1000° C. to 1100° C. and is therefore thermally very challenging both for the IR-stimulable material and also for the operation of the heating device. The IR-stimulable material can firstly be applied as a coating on the thermal insulation, for example on the areas or regions of the thermal insulation which can be readily identified from the outside and/or from above. A thermal insulation of this kind can be formed, for example, in accordance with U.S. Pat. No. 5,834,740 A, as is frequently used for radiant heating devices. This surface of this thermal insulation is suitable for surface-area coatings which are not overly fine or detailed.
[0017] Secondly, the IR-stimulable material can also be mixed into the material of the thermal insulation, for example into the quantum dots directly, and therefore integral production, for example in the form of pressing, can be performed. However, in this case, the requirements made of an IR-stimulable material of this kind are very high for the relatively low proportion which is then later provided on surfaces which are visible from above.
[0018] Certain areas of the thermal insulation which are directed upwards or can be particularly easily identified from above can preferably be provided with the IR-stimulable material. This can be, for example, an edge region of the support or of the thermal insulation which surrounds the resistance heater, or as an alternative a free central region.
[0019] In a yet further alternative refinement of the invention, the IR-stimulable material can also be provided directly on the heating device, specifically directly on the resistance heater. This is possible primarily when the resistance heater is an abovementioned tubular heating body of which the surface or outer shell, usually a metal tube, reaches temperatures of less than 1000° C., that is to say is less hot than an abovementioned exposed resistance heater of a radiant heating body.
[0020] In general, it is considered advantageous when regions of this kind are provided or coated with IR-stimulable material and can be easily identified from above. For example, in the case of a resistance heater in the form of a tubular heating body, coating of the tubular heating body does not need to be provided over the entire circumference, rather coating on the top face with IR-stimulable material is sufficient.
[0021] As an alternative, the IR-stimulable material can be applied to a support which is fitted on the heating device, the support corresponding to the abovementioned additional support which can advantageously be composed of metal, glass or glass ceramic. The support can be arranged between the heating device and the hob plate. In a further refinement of the invention, the support between the heating device and the hob plate can be in the form of a light guide or light channel.
[0022] In an advantageous development of the invention, a material comprising two different quantum dots or two different types of quantum dots can be provided, the quantum dots being designed to display two different colors during operation as an indicator light. The two different colors are then produced by different application at different temperatures. Therefore, not only is an indicator light or lighting means which is tripped by IR or thermal radiation possible on a hob, but rather an indicator light which is a different color depending on the temperature is also possible. This is advantageous, for example, for residual-heat indicators on a hob.
[0023] In a refinement of the invention, thermochromic material can be provided in a layer structure over the IR-stimulable material. A layer structure which is intended to be provided on the hob plate or on the bottom face of the hob plate or beneath the hob plate can be selected here. In this case, it is considered to be advantageous when the extent of the thermochromic material is approximately exactly the same as that of the IR-stimulable material beneath it, and it should at least have the same surface-area coverage. As an alternative, it is also possible for certain regions to be covered and for certain regions to be exposed, so that, when a specific temperature for this thermochromic material is exceeded, an IR-stimulable material which is situated beneath the thermochromic material first becomes visible when the thermochromic material changes color.
[0024] In order to produce a coating comprising the IR-stimulable material or comprising quantum dots, a starting material, often a powder, can be processed in a dispersion. This can, in turn, be admixed with a dispersion material such as a dye or other carrier material. This can then, in turn, be mixed in or applied as desired.
[0025] These and further features are apparent not only from the claims but also from the description and the drawings, where the individual features can in each case be realized on their own or jointly in the form of subcombinations in an embodiment of the invention and in other fields and can constitute advantageous and inherently protectable embodiments for which protection is claimed here. The subdivision of the application into individual sections and subheadings does not restrict the general validity of the statements made thereunder.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0026] Exemplary embodiments of the invention are schematically illustrated in the drawings and will be explained in greater detail in the text which follows. In the drawings:
[0027] FIG. 1 shows a section through a hob according to the invention comprising a radiant heating body to which IR-stimulable or quantum dot coatings are applied in different ways;
[0028] FIG. 2 shows a section through a tubular heating body as an alternative heating device;
[0029] FIG. 3 shows a schematic illustration of a multilayer coating with a thermochromic coating over a quantum dot coating;
[0030] FIG. 4 shows a plan view of the hob according to FIG. 1 with a radiant heating body illustrated using a dashed line and a lighting ring, illustrated using a dotted line, of a luminous quantum dot coating; and
[0031] FIG. 5 shows a radiation spectrum of quantum dots with two main wavelength ranges of the radiation.
DETAILED DESCRIPTION
[0032] FIG. 1 shows a section through a hob 11 according to the invention which is designed largely in a conventional manner. The hob has a hob plate 13 , advantageously a hob plate which is composed of glass ceramic such as, for example, KeraVision from EuroKera or Hightrans from SCHOTT. A radiant heating body 16 is pressed onto a bottom face 14 of the hob plate 13 , as is customary. The hob can have a plurality of such radiant heating bodies.
[0033] The radiant heating body 16 is constructed largely in accordance with the abovementioned prior art and has a plate- or board-like support 17 which is composed of thermally insulating material. A circumferential support edge 18 is mounted or integrally formed on the outside of the radiant heating body. Under certain circumstances, the support 17 which is composed of thermally insulating material can also be held in the manner of a sheet-metal plate, but this is not important for the invention. An oblique edge fillet 19 can be provided between the support edge 18 and the support 17 . A resistance heater 21 is arranged in a standing manner on the support 17 . The resistance heater is in the form of an upright flat strip and runs in a spiral or meandering manner on the support 17 .
[0034] A coating comprising IR-stimulable material, here comprising material comprising quantum dots, can be arranged on the radiant heating body 16 and/or the support 17 or the support edge 18 in different ways. A first possibility is a quantum dot coating 23 a on the top face of the support edge 18 . The quantum dot coating can extend around the entire circumference or form individual points, regions, symbols or the like. Since this quantum dot coating 23 a is pressed directly onto the bottom face 14 of the hob plate 13 , it is very clearly visible from above. However, at the same time, it may be possible that only a small extent of the said quantum dot coating can be reached by the IR radiation of the resistance heater 21 of the radiant heating body 16 . An IR-stimulable material of this kind can either have quantum dots with erbium doping from the start or be designed in accordance with the abovementioned document U.S. Pat. No. 4,806,772 A.
[0035] A further IR-stimulable quantum dot coating 23 b is provided on the inwardly facing side of the support edge 18 . The further IR-stimulable quantum dot coating can also be formed entirely or largely circumferentially as a kind of ring, or as an alternative individual points or the like, as has been explained above for the quantum dot coating 23 a. Although the quantum dot coating 23 b on the sides of the support edge 18 is less clearly visible from above, it can be very readily irradiated by the IR radiation of the resistance heater 21 .
[0036] A further IR stimulable quantum dot coating 23 c is applied on the edge fillet 19 which is additionally provided for this purpose. This quantum dot coating 23 c can be both identified very clearly from above and also can be readily irradiated by the IR radiation of the resistance heater 21 . Coating can also be performed in different forms, as long or even continuous strips, or as an alternative as individual points, symbols or the like, here.
[0037] According to a further possibility, an IR-stimulable quantum dot coating 23 d can be applied on the support 17 or the top face of the support, for example centrally, but also at the edge region. Although a particularly large surface area may not be available here under certain circumstances, both visibility and ability to irradiate are very good.
[0038] A further possibility for an IR-stimulable coating is a quantum dot coating 23 e on the bottom face 14 of the hob plate 13 . The quantum dot coating has the advantage that it is both very clearly visible from above and can be irradiated very readily by the IR radiation of the resistance heater 21 . However, the quantum dot coating has the disadvantage that it is not applied to the radiant heating body 16 itself, but rather just to the hob plate 13 . Therefore, it has to be applied in completely different working steps.
[0039] As an alternative to a coating, a foil, a glass panel or some other suitable support on which a quantum dot coating 23 is applied can be stuck on in each case.
[0040] FIG. 2 shows an alternative heating device, as could be used for an oven or else for a hob. A tubular heating body 116 has a metal tube in which a heating wire 121 runs. In addition, the tube is filled with pulverulent or granular insulating material. A tubular heating body 116 of this kind can be designed in the manner cited in the introductory part and form the abovementioned resistance heater.
[0041] An IR-stimulable quantum dot coating 123 is applied on the tubular heating body 116 at the top. The IR-stimulable quantum dot coating can cover substantially the top half, but, for example, also only a top third or a top quarter which can also be seen or can be identified as clearly as possible from above. Although the resistance heaters 21 of the radiant heating body 16 of FIG. 1 can be provided directly with a quantum dot coating, the high temperatures of the resistance heaters during heating operation of approximately 1100° C. make coating difficult. In addition, the degree of efficiency could be adversely affected.
[0042] FIG. 3 schematically shows a layer structure comprising an IR-stimulable quantum dot coating 23 on which a thermochromic coating 25 is arranged. As has been described above, the thermochromic coating 25 can change its color or even become transparent at a certain temperature. Therefore, a quantum dot coating 23 which is situated beneath the thermochromic coating becomes visible or is no longer visible at this temperature. Furthermore, the color may change owing to the thermochromic coating 25 . With reference to FIG. 3 , it is also easy to imagine how a layer structure with still more layers could be formed, for example even a plurality of IR-stimulable quantum dot coatings one above the other.
[0043] FIG. 4 shows a plan view of the hob 11 from FIG. 1 with lights of an IR-stimulable quantum dot coating 23 c as indicator light 24 in the form of a circumferential lighting ring, illustrated using a dotted line. This indicator light 24 can be identified through the hob plate 13 and can constitute, for example, an operation indicator or heat indicator for the radiant heating body 16 or the heating operation of the radiant heating body.
[0044] FIG. 5 shows an emission spectrum of an IR-stimulable quantum dot coating or of material comprising quantum dots. The quantum dots are quantum dots from CAN, Hamburg, with the name CANdots Series X Green. These quantum dots comprise so-called “core” particles which are composed of NaYF 4: Yb, Er. This is the lower curve with the very small deflections at approximately 540 nm and 650 nm. The deflections can be excited to light up by IR radiation.
[0045] Furthermore, the upper curve for quantum dots comprising so-called “core/shell” particles is shown. The core/shell particles are composed of NaYF 4: Yb, Er/NaYF 4 . The maxima of this emission or radiation are far higher but, in principle, are found in approximately the same wavelength. The color produced is then green. The respective IR-stimulable materials comprising quantum dots are irradiated with near-field IR light with a wavelength of 980 nm, for example as is contained in the spectrum of the radiant heating body 16 or of the resistance heater 21 during heating operation. | A hob has a hob plate and a plurality of heating devices arranged beneath the hob plate, wherein the hob plate is designed such that it transmits light in the wavelength range visible to the human eye. The heating device has an electrical resistance heater arranged on a support with thermal insulation. IR-stimulable material including quantum dots is arranged as an indicator light or lighting means on the resistance heater or on the thermal insulation or on the hob plate. The IR-stimulable material is formed in such a way that it can be excited to output light for the indicator light by excitation light in the IR wavelength range. | 7 |
RELATED APPLICATION
[0001] This application is a divisional for co-pending U.S. patent application Ser. No. 09/521,736, filed Mar. 9, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to processes and apparatus for applying tabs to traveling webs. The invention has particular applicability to the manufacture of disposable diapers.
[0003] The history of cutting and applying tape tabs to disposable diaper webs is now entering its fourth decade. Over the course of that time, various types of automatic manufacturing equipment have been developed which produce the desired results with a variety of materials and configurations. This equipment generally included window-knife and slip-and-cut applicators, each having their own advantages and limitations.
[0004] Window-knife applicators are comprised of: one or more rotating heads, each made up of a knife edge and a vacuum plate; a more or less stationary knife, which is configured with a hole (window); and a tape transfer mechanism. Typically, the rotating heads are mechanically configured so as to eliminate head rotation relative to the stationary knife. Each head is passed, once per cycle, across the face of the stationary window knife, through which the infeeding tape is passed. The rotating knife shears the extended length of tape against the sharp inner edge of the hole (window), after which the severed segment is held by the vacuum plate. The rotating head, with the segment of tape held in place by the vacuum plate, continues through its rotation to a point, usually 90 degrees later, where it contacts the traveling web, which is pressed against the exposed adhesive of the tape segment. This contact, usually against some backing device, effects a transfer of the tape tab from the vacuum plate to the traveling web, which then carries the tape tab downstream.
[0005] Window-knife applicators have a few shortcomings, among which are: the difficulty in feeding tape webs with little axial stiffness; the tendency of the infeeding tape to adhere to the window knife-edge; and for exposed adhesive to contaminate the surfaces of the window knife. For effective cutting, some degree of interference between the cutting edges is necessary between the moving and stationary knife faces, so to minimize impact, precision in manufacturing must be maintained and provision must be made for a degree of resiliency. While applicators of this type have been tested to speeds of 1000 cuts per minute, the maximum practical speed capability of current designs is approximately 750 cuts per minute.
[0006] Slip-and-cut applicators are typically comprised of (a) a cylindrical rotating vacuum anvil (b) a rotating knife roll and (c) a transfer device. In typical applications, a tape web is fed at a relatively low speed along the vacuum face of the rotating anvil, which is moving at a relatively higher surface speed and upon which the tape web is allowed to “slip”. A knife-edge, mounted on the rotating knife roll, cuts a segment of tape from the tape web against the anvil face. This knife-edge is preferably moving at a surface velocity similar to that of the anvil's circumference. Once cut, the tape tab is held by vacuum drawn through holes on the anvil's face as it is carried at the anvil's speed downstream to the transfer point where the tape segment is transferred to the traveling web.
[0007] A common problem with slip-and-cut applicators lies in the tendency to accumulate various contaminants on their anvil surfaces. This is most frequently seen in the form of the release compounds found on the non-adhesive side of tape, which is shipped on pre-wound rolls. Where die-cut tapes are fed onto the surfaces of slip-and-cut applicators, it is common to also see an accumulation of adhesive contamination, as the adhesive has been exposed at the tape edges by the die-cutting process. The difference in speed between the tape web and the anvil tends to “wipe” adhesive from the tape web. Contamination of the anvil, whether by release compounds or by fugitive adhesive, interferes with the regularity of slip occurring between the tape and the anvil, causing registration and cut accuracy problems. Frequent cleaning is necessary to maintain any level of productivity.
[0008] Another problem associated with slip-and-cut applicators occurs at the point of cut. Since the web being cut is traveling at a very low velocity compared to the anvil and knife velocity (perhaps {fraction (1/20)} th ), the engagement of the knife with the tape web tends to induce a high tensile strain in the tape web. Having been placed under such a high level of stress, the tape web can recoil violently when the cut is finally completed, causing loss of control of the tape web. This “snap-back” effect increases with the thickness of the tape web. Thicker webs tend to prolong the duration of engagement with the knife before completion of the cut, thereby increasing the build-up of strain. This is a common process problem that is usually addressed by the provision of various shock-absorbing devices. One possible solution might have been to reduce the surface velocity of the knife, but substantially different velocities between the knife and anvil result in rapid wear of the knife edge and/or anvil face, depending on relative hardness.
[0009] Continual improvements and competitive pressures have incrementally increased the operational speeds of disposable diaper converters. As speeds increased, the mechanical integrity and operational capabilities of the applicators had to be improved accordingly. As a further complication, the complexity of the tape tabs being attached has also increased. Consumer product manufacturers are offering tapes which are die-cut to complex profiles and which may be constructed of materials incompatible with existing applicators. For instance, a proposed tape tab may be a die-profiled elastic textile, instead of a typical straight-cut stiff-paper and plastic type used in the past. Consequently, a manufacturer may find itself with a window-knife applicator, which cannot feed a tape web with too little axial stiffness. It could also find itself with a slip-and-cut applicator, which cannot successfully apply die-cut tape segments. Furthermore, existing applicators cannot successfully apply tapes whose boundaries are fully profiled, as may be desired to eliminate sharp corners, which might irritate a baby's delicate skin. This demonstrates a clear need for an improved applicator capable of applying new tape configurations and overcoming other shortcomings of prior art applicators.
SUMMARY OF THE INVENTION
[0010] A basic premise of all applicators using prior art has been to cut the tape at one velocity and then to carry it at its final velocity to the transfer point. The assumption has been made that for correct and accurate placement, the tape tab must be moving at the final web velocity. The proposed invention diverges from that premise, eliminating or reducing the shortcomings associated with prior devices.
[0011] In accordance with an important aspect of the invention tape segments are cut and carried at a very low tape web infeed speed. In accordance with a related aspect, problems with transferring a slow-moving segment to a fast-moving web are overcome. Additionally, die-cutting of tape segments to any number of practical shapes is possible, thereby avoiding difficulties associated with prior attempts to do so using previous applicator technology, which required multiple steps to accomplish the same task.
[0012] The invention provides the additional benefit of quiet operation compared to prior art equipment, which uses high speed cutting faces and suffers from the effects of the very high energy levels seen at the point of contact. Generally, these energies, and the sounds that they generate, increase in proportion to the square of the velocity. The present invention benefits from the relatively low speed of the cutting faces and exhibits extremely low noise levels. In fact, the underlying noise of the mechanical drive systems and the traveling web equipment contribute to make the cutting noise level nearly unnoticeable.
[0013] The present invention provides a simplified process wherein a rotary knife or die, with one or more cutting edges, turns against and in coordination with a corresponding vacuum anvil cylinder. An infeeding tape web is fed along the surface of the anvil, which is rotating at a surface velocity equal to or only somewhat greater than that of the tape web. As the tape web passes the nip created between the knife-edges and the anvil surface, segments of tape are parted but not significantly displaced upon the anvil surface. The segments continue downstream on the anvil surface, held securely by forces induced by a vacuum source directed to one or more holes provided for each segment in the anvil surface.
[0014] At a point downstream along the surface of the anvil, the traveling web to which the segments are to be attached is brought into close proximity with the anvil and its tape segments. A mechanically operated device, which may be as simple as a protuberance on a rotating cylinder, presses the target zone of the traveling web against the exposed adhesive of the tape segment as it is presented on the anvil surface. The protuberance preferably has a surface velocity substantially identical to that of the traveling web. Given the extremely low moment of inertia of the tape segment and the aggressive adhesion provided between its exposed adhesive and the compatible surface of the traveling web, each successive segment is successfully transferred to the traveling web, accelerating almost instantly to the speed of the traveling web.
[0015] A key aspect of this invention lies in the method and apparatus used to effect the transfer of the tape segments from the anvil to the traveling web. In accordance with the invention, a vacuum commutation system is configured to remove or reduce the level of vacuum used to hold each tape segment to the anvil surface just before the point of transfer. The materials and finishes selected for the anvil and the transfer protuberance provide a situation in which the coefficient of friction between the protuberance and the traveling web is relatively high, while the coefficient of friction between the tape segment and the anvil is relatively low. The highly aggressive nature of the bond between the adhesive side of the tape segment and the target surface of the traveling web ensures that there is virtually no slippage between the two. This ensures that the traveling web is driven through the point of transfer at its existing velocity, and that any tendency of the tape segment to adhere to the anvil surface will not influence the traveling web. The process requires that some slip occurs, and in accordance with the invention, slip occurs only between the tape segment and the anvil surface.
[0016] This method is extremely effective in that 25 mm tape segments can be accurately transferred at 800 mm spacing to webs traveling at 300 meters per minute or more. This is a web-to-tape velocity ratio of 32:1. Tape to tape positional accuracy has been found to be extremely precise, with standard deviations of less than 1 mm when applied at a 800 mm spacing. Additionally, a speed capability of more than 2,400 tapes per minute is achievable, easily exceeding the limits of any previously known disposable paper product manufacturing process.
[0017] Further objects and advantages of the invention will be apparent from the following detailed description, the attached claims and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a diagrammatic side view of a Prior Art process;
[0019] [0019]FIG. 2 is a diagrammatic side view illustrating a preferred process of this invention;
[0020] [0020]FIG. 3 is a side view illustrating a further embodiment of the invention;
[0021] [0021]FIG. 4 is a front elevational view of the equipment of FIG. 3 viewed from the right hand side of FIG. 3;
[0022] [0022]FIG. 5 is a side elevational view of yet another embodiment of the invention;
[0023] [0023]FIG. 6 is a front elevational view of the apparatus shown in FIG. 5 as viewed from the right hand side of FIG. 5;
[0024] [0024]FIG. 7 is a perspective view in somewhat diagrammatic form illustrating a further embodiment of the invention; and,
[0025] [0025]FIG. 8 is a diagrammatic side elevational view illustrating yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring more particularly to the drawings there is seen in FIG. 1 a diagrammatic illustration of a prior art process for applying tabs to webs in a diaper making process. Web 10 is a composite material used in formation of diapers which is generally formed of various layers of material such as plastic back sheets, absorbent pads and nonwoven topsheets. A series of tape segments 12 are applied to web 10 . In the illustrated process a rotatable vacuum anvil 14 is used to supply the tabs 12 which have an outwardly facing adhesive coated surface used to adhere the tabs 12 to web 10 . Anvil 14 has internally reduced air pressure or vacuum, and a plurality of openings 24 are provided through its surface to enable suction of the tabs segments 12 against the anvil surface 14 . A web of the tape tab forming material 16 is fed by rollers 20 and 22 against the anvil surface 14 where it is cut into segments by a rotary knife 18 .
[0027] In this prior art application the anvil 14 is rotated at a speed such that its outer perimeter, and thus the tabs 12 carried thereby, are moving at a speed approximately equal to that of web 10 . This causes a great deal of slippage to occur between the anvil 14 and the lower speed infeeding web 16 .
[0028] Referring to FIG. 2, the apparatus and process of this invention is shown in diagrammatic fashion. In accordance with the invention, the web 16 is fed to the anvil 24 at a speed such that the web speed of web 16 approximately equals the speed at which the outer periphery of anvil 14 is traveling. If desired, the anvil 14 may rotate at a slightly higher speed than the linear speed of the web 16 . The blades 34 of a rotary cutter 32 are also traveling at a peripheral speed equal to that of anvil 14 . As seen in FIG. 2, after cutting, a series of tabs 12 are carried on the outer surface of anvil 14 . Tabs 12 are held in place by vacuum provided within the interior of anvil 14 . The adhesive-coated surface of web 16 is facing outwardly while a non-tacky or uncoated surface engages the exterior anvil 14 .
[0029] A web 10 of diaper material is caused to travel in a path slightly displaced from the outer surface of rotating anvil 14 , but in close proximity thereto. Just above the web 10 is a rotating wheel 38 , which rotates at a peripheral velocity equal to the lineal velocity of web 10 , which, in turn, is substantially greater than the peripheral velocity of anvil 14 . Anvil 14 may travel at a peripheral velocity either equal to or somewhat greater than the velocity of web 10 . In practice, to realize the benefits of this invention, the peripheral velocity of anvil 14 should not be greater than about 5 times the velocity of web 10 .
[0030] Wheel 38 , as seen in FIG. 2, has a protrusion 36 which extends along its width. The rotational speed of roller 38 is selected so that the protrusion 36 engages web 10 and displaces it into contact with each successive adhesive-coated tab 12 . The slight displacement of web 10 causes it to come into contact with the tab segment 12 which, then, is instantly adhered to the higher speed traveling web 10 . The coefficient of friction between the uncoated side of tab 12 and the metal surface of anvil 14 is low so that the aggressive adhesion between tab 12 and web 10 together with the extremely low moment of inertia of tape tab segment 12 facilitates successful transfer of the tabs 12 to the web 10 , the tabs 12 accelerating almost instantly to the higher speed of web 10 .
[0031] To further facilitate the transfer of tabs 12 to web 10 , a vacuum commutation is provided to remove or substantially reduce the level of vacuum used to hold tape segments 12 to the anvil surface 14 just before the point of transfer. For this purpose, an interior arcuate plenum 25 is situated within anvil 14 in order to provide vacuum only along the portion of anvil 14 which engages web 16 up to a location just short of the transfer point. Thus, the portion of the anvil 14 which does not engage web 16 or tabs 12 is not provided with vacuum.
[0032] While the drawings show the protrusions 36 on cylinder 38 in somewhat exaggerated form, in practice the protrusions 36 can simply be in the form of a lobe on the cylindrical surface as low as 0.030 inch in height, but may, if desired, be of a much greater height.
[0033] Referring to FIGS. 3 and 4, there is seen an arrangement of the apparatus of this invention generally more suited for commercial operation. As viewed in FIG. 3, web 10 is travelling to the left and adhesive-backed tape 16 is fed over a roller 121 onto anvil/drum 114 . Tape web 16 is cut into individual tape tabs by a rotary cutter 132 . As the tape tab segments 12 travel to the top of drum 114 as viewed in FIG. 3, the web 10 is intermittently impacted by lobes 136 located on opposite sides of rotatable wheel 138 . The apparatus is driven by a motor or power supply 130 through various mechanical drive connections generally shown by dotted or phantom lines in FIG. 4.
[0034] As viewed in FIG. 4, a second laterally displaced anvil 115 receives another tape web 16 which is cut into tab segments 12 by blades 135 on a rotary cutter 133 . A pair of lobes or protrusions 139 on a rotatable wheel 137 cause the web 10 to pick up each successive tab segment 12 from the anvil 115 just as in the case of the other anvil 114 . In this manner, tape tabs 12 are applied to each lateral edge of a web which is subsequently formed into a diaper product. These tape tabs 12 may have ends provided with hook and loop fasteners or other fastening means selected for use in connection with the diaper product.
[0035] Also, as seen in FIG. 4, the rotatable anvils 114 and 115 are rotatably driven by a shaft 140 . Similarly, rotary cutters 132 and 133 are mounted on another shaft 142 while the rotatable disks 138 and 137 are mounted on another shaft 144 .
[0036] In FIGS. 5 and 6 there is seen still another embodiment of the invention particularly suited to manufacture of baby diapers having tape tabs thereon. In this case the rotatable anvil 70 , as viewed in FIG. 5, is similar to anvil 14 previously described in detail. A rotary cutter 72 is provided with cutting blades just as in the case of cutter 32 . In this embodiment a rotatable bar 74 is provided with ends 76 and 78 that serve to push a traveling web against a succession of tabs 12 carried by the anvil 70 . In other respects the apparatus and operation of the device shown in FIGS. 5 and 6 is similar to that previously described. As seen in FIG. 6 a second anvil 71 is engaged by a second rotary cutter 73 to cut a second series of tabs for the lateral side of the diapers opposite that engaged by anvil 70 . A second rotary bar 75 is provided with lobes 77 and 79 which serve in the same fashion as lobes 76 and 78 of rotary bar 74 . Also as seen, the anvils 70 and 71 are rotatably mounted on a shaft 80 and rotatable bars 74 and 75 are rotatably mounted on a shaft 82 while cutters 72 and 73 are mounted on shafts 81 and 83 , respectively. All of these devices may be driven, as shown, by a supply of power from a rotating shaft 84 driven by a power supply common to other components of the production line. The arrangement of drive belts, etc., as shown for purposes of illustration, but does not form a part of the invention, since such components of the production line would routinely be designed by engineers skilled in the art.
[0037] In FIG. 7 there is shown, for purposes of clarity, a simplified device in accordance with the invention, illustrating the application of tabs 52 and 54 which have free ends extending laterally from opposite sides of a diaper-forming web 50 . These free ends of tabs 52 and 54 may be provided with loops on one side of the diaper-forming material and hooks on the opposite side to form hook and loop fasteners on the diapers commonly referred to as Velcro®. In other cases, the tabs on at least one side may be coated with a pressure sensitive adhesive protected until use by a release layer
[0038] As further seen in FIG. 7, an adhesive-coated tape web 61 is fed over a roller 64 onto an anvil 60 similar to anvil 14 previously described. A similar anvil 62 engages a second adhesive-coated web. These webs may have adhesive coated on one-half of their width and a hook or loop-type fastener provided on the opposite half of the width in order to form the laterally extending tabs 52 and 54 . These webs are cut by blades 56 of rotary cutters 58 and blades 57 of a second rotary cutter 59 , respectively. As seen, both of the cutters 58 and 59 are driven by a rotatable shaft 55 . Similarly, anvils 60 and 62 are driven by a central shaft 63 . Rotatable disks 66 and 68 provided with protrusions 65 and 67 serve to deflect the edges of the web 50 toward the respective anvils 60 and 62 in order to simultaneously pick up the tabs 54 and 52 on opposite sides of the web 50 , as shown.
[0039] A still further alternative embodiment of the invention is illustrated in FIG. 8. In this embodiment, a diaper-forming web 210 is intermittently coated with adhesive deposits 204 along the edge of the web 210 . A tab-forming web 202 is fed over a hollow vacuum anvil 216 and cut thereagainst into a series of tabs 208 by blades 219 of a rotary cutter 218 . An intermediate transfer roll 214 also provided with internal vacuum is used to transport the tabs 208 into close proximity with the bottom of web 210 . Again, a traveling drum 238 having lobes 236 is traveling at a speed such that a lobe 236 contacts the web 210 just as an adhesive-coated area 204 is aligned with one of the tabs 208 . Displacement caused by action of the lobe 236 against the web 210 causes the each tab 208 to become adhered to one of the adhesive coated areas 204 . In other respects the operation of the device of FIG. 8 is similar to that previously heretofore described.
[0040] The foregoing descriptions are set forth for illustrative purposes rather than by way of limitation, since it will be apparent to those skilled in the art that various additional embodiments exemplifying the principles of the invention may be devised. | This invention provides a method and apparatus for applying tape tabs to a traveling web, for example, for placement of fastening tabs on a running web of disposable diapers. The invention provides a cutting roll positioned to cut segments from a continuous infeeding web of tape material against a rotating anvil. The anvil, which is traveling at a speed equal to or very close to that of the infeeding tape web, carries the tape segments to a point on its tangency where a higher-speed traveling diaper web most nearly approaches, at which point the traveling diaper web is displaced slightly toward the anvil by means of a protuberance acting against the web. This movement causes it to come into contact with the next available tape segment, which becomes adhered to the higher-speed traveling web. This process provides for operation at higher speeds, higher efficiencies, greater flexibility and lower noise levels than previous processes. | 1 |
FIELD OF THE INVENTION
The present invention relates generally to lubrication systems, and more particularly to a new and useful arrangement of components for an air compressor lubrication system. As illustrated and described below, the system has particular utility in a Westinghouse "3-CD" series two stage air compressor or similar unit.
BACKGROUND OF THE INVENTION
The lubrication system utilized in most air compressors, including the Westinghouse "3-CD" series two stage air compressor, has remained virtually unchanged since the 1940's. Ensuring adequate lubrication, however, has been a continuing design problem.
The lubrication system presently utilized in many compressors draws oil or other lubricating fluid from a sump located within the crankcase, in the same manner that water is "drawn" from a farmer's hand well pump. This lubrication system typically comprises a cartridge having inlet and discharge check valves, a hollow pump plunger having one end driven off an eccentric on the crankshaft to provide both an oscillating and reciprocating motion, and a pump body to house the plunger and cartridge. In operation, rotation of the crankshaft causes the plunger to reciprocate in the pump body, thereby drawing lubricating fluid from an underlying sump through the cartridge inlet and discharge check valves and into the plunger's hollow interior. From the interior of the plunger, lubricating fluid is directed through passageways associated with the crankshaft to wear areas by means of positive pressure.
It has been found that the single reciprocating pumping action of present lubrication systems results in undesirable pressure pulses. Moreover, such systems have been found to provide a relatively low output volume and pressure. To overcome these deficiencies, the present invention employs a positive displacement rotary pump capable of delivering a continuous flow of lubricating fluid, thereby providing a significantly higher overall system pressure and volume.
Conventional lubricating systems also provide only minimal filtration of the lubricating fluid through use of a coarse screen, typically placed in front of the pump inlet. The present invention recognizes the need for increased filtration of the lubricating fluid to minimize wear of the pump and compressor and thus calls for a replaceable filter module which is mountably attached to a removable inspection plate on the exterior of the compressor. This combination of an externally mounted filter module and removable inspection plate provides for the removal of particulate matter which can greatly reduce the useful life of bearings and other moving components, while at the same time providing a viewing port for inspection and maintenance.
OBJECTS AND SUMMARY OF THE INVENTION
The primary object of the present invention is to provide an improved lubrication system for air compressors such as the Westinghouse "3-CD" series and similar units. It is a related object to provide a lubrication system which produces a pressure which is both higher and more constant than that obtained by the plunger-driven reciprocating pumps presently employed. These objects are realized through use of a positive displacement gear-driven pump in series with a readily replaceable filtration medium. As will be described in greater detail hereinafter, lubricating fluid flows from the replaceable filter to an opening in the crankshaft, thereby allowing flow through internal passages within the crankshaft to areas requiring lubrication.
Unlike a reciprocating pump, which delivers lubricating fluid in a pulsating fashion, giving rise to fluctuations in system pressure, the positive displacement pump utilized herein provides a continuous and steady flow of lubricating fluid to the crankshaft. The lubrication system of the present invention thus ensures that the flow of lubricating fluid to areas requiring lubrication--especially those areas at a substantial distance from the crankshaft inlet port--will not be subject to sporadic interruption. Such sporadic lubrication can, of course, lead to the premature wear of moving parts, thereby necessitating costly and time-consuming repairs.
Another object of the present invention is to provide improved filtration of the lubricating fluid while at the same time facilitating maintenance and inspection of the filter medium and the lubrication system. To this end, the present invention employs a replaceable filter cartridge which is mounted on a removable plate on the exterior of the compressor. Removal of the plate permits inspection of the filter feed lines, the pump, and the pump's associated drive mechanism.
These and other objects and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exterior view of an air compressor which utilizes the lubrication system of the present invention.
FIG. 2 is a detail of the filter unit of the lubrication system and shows the filter cartridge mounted on a removable exterior inspection plate.
FIG. 3 is a perspective view of the positive displacement pump of the present invention located within an internal crankcase chamber and the backside of the inspection plate.
FIG. 4 is a side view of the compressor crankshaft depicting the arrangement of the pumping and distribution components of the lubrication system of the present invention.
FIG. 5 is an elevational view of the lubricating fluid distribution ring which is shown in side view in FIG. 4.
While the present invention will be described and disclosed in connection with certain preferred embodiments, it is not intended to limit the invention to those specific embodiments. Rather, it is the applicant's intention to cover all such alternative embodiments and modifications as fall within the spirit and scope of the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, an air compressor 10 is shown generally in FIG. 1. Although those skilled in this art will recognize the compressor as a Westinghouse type "3-CD" series, the invention is not intended to be limited solely to such compressors but may be used in other compressors, and machinery having rotatable drive members. Nevertheless, a brief description of the configuration and operation of a Westinghouse "3-CD" series compressor is useful to an understanding of the preferred embodiment of the present invention.
The Westinghouse "3-CD" air compressor is a two stage compressive unit. The compressor is operated by means of a central crankshaft 12 journaled in a crankcase having an internal chamber. The central crankshaft may be rotated by any appropriate power source (not shown), including an electric or diesel engine. Rotation of the crankshaft 12 causes pistons to move in a reciprocating manner in compression cylinders 15, 16 and 17. Each cylinder includes a body portion 19 and a head portion 20. Gasket means are interposed between the body portion 19 and the main compressor structure, and at the interface between the body portion 19 and the cylinder head 20.
When the compressor 10 is in operation, air is drawn from ambient through a filter unit (not shown) during the downstroke of the piston, through an inlet port (not shown) on the cylinder head 20 of cylinders 15 and 16. During the upstroke of the piston the air in the cylinder is compressed to approximately 40 psig and is expelled through outlet port 23. The compressed air then passes through a right hand riser 24 and left hand riser 25 connected to compression cylinders 15 and 16, respectively. The compressed air, which has increased in temperature due to the initial compression in cylinders 15 and 16, is then passed through intercooler core sections 26, 27. There the temperature of the compressed air is reduced by conventional conductive and convective heat transfer techniques. The cooled, compressed air is thereafter delivered from the separate intercooler core sections 26, 27 to a central manifold 28. The combined flow of compressed air is then passed into inlet port 29 of compression cylinder 17. The air is then further compressed through movement of the piston within cylinder 17 in the same manner as previously described in relation to cylinders 15 and 16. Following this second stage of compression, the air is expelled through an exhaust port (not visible) in the cylinder head of compression cylinder 17 at a pressure of approximately 140 psig. The compressed air is thereafter conveyed to storage tanks for later use.
Keeping in mind the compressor operation described above, the lubrication system of the present invention is operatively connected to the crankshaft 12 to continuously pump lubricating fluid through an externally mounted filter cartridge 30 to wear areas within the compressor. The replaceable filter cartridge 30 is externally mounted on a crankcase inspection plate 32, which is readily removable to afford access to the internal crankcase chamber and pumping mechanism shown most clearly in FIG. 3.
The filter cartridge 30 may be comprised of an internal filter element (not shown) and an external filter case 34, having a removable cap 36. Alternatively, the filter cartridge can be unitary, so that the filter media and filter case can be replaced as a unit. The filter element may be formed from any appropriate filter media capable of providing efficient particulate removal while remaining chemically nonreactive with respect to the lubricating fluid being processed. The external filter case may be formed from any material suitable to house and protect the filter media. In addition, the filter cap will preferably include external ridges which provide a gripping surface to facilitate removal and replacement of the cap when the filter element is replaced or cleaned, or removal of the filter case when the cap and case are a unitary construction.
The rotary pump 40 and associated elements are most clearly seen in FIG. 3. In the preferred embodiment, lubricating fluid is drawn by a rotary pump 40, such as a Tuthill Model #1RFD-1 or the like, from a sump (not shown) located in the lower portion of the compressor structure. The lubricating fluid is carried from the sump to the pump via first delivery means such as transfer line 41. The lubricating fluid is drawn into pump 40 through inlet 42 at a relatively low pressure and is discharged through outlet 43 at a significantly higher pressure. The pump 40 is operatively coupled to the crankshaft by power transfer means which in the preferred embodiment include a drive gear 45 and pump drive gear 46, and as shown in FIG. 4 is mounted on a sidewall of the compressor structure. The crankshaft drive gear 45 is mounted on and is rotated via revolution of crankshaft 12. Pump drive gear 46 is mounted on rotary pump 40 and intermeshes with crankshaft drive gear 45 so as to facilitate steady power transfer to the rotary pump 40.
The ratios of the intermeshing crankshaft drive gear 45 and pump drive gear 46 will be selected to impart the drive speed to rotary pump 40 which is necessary to operate within the desired range of pressure and volumetric flow. This optimum operational drive speed is dependent upon the specific rotary pump 40 which is selected and will, in normal instances, be readily determined from characteristic data curves supplied by the pump manufacturer.
An important aspect of the preferred embodiment of the present invention is the use of a rotary pump 40 which may be operated by rotation of the pump drive gear 46 in either a clockwise or counter-clockwise direction. The use of a rotary pump with this capability allows the rotary pump to be driven from either end of crankshaft 12, thereby affording the user a greater degree of freedom in orienting the components of the lubrication system with respect to the main compressor housing and crankshaft.
Upon discharge from rotary pump 40, the lubricating fluid is conveyed by positive pressure through a second delivery means such as flexible transfer line 50 to the filter inlet 52. After passing through the filter element, the lubricating fluid passes through a relief valve housing 54 as most clearly seen in FIGS. 1 and 2. The relief valve contained within this housing is adjustable by means of a set bolt 55 to permit the increase or decrease of the system operating pressure and is of conventional design. As contemplated, the relief valve serves to protect the filter module and other components of the system from fluid pressure in excess of safe operational limits. Fluid above the set pressure of the relief valve is bypassed through the inspection plate through delivery means such as conduit 60 to the crankcase sump.
Lubricating fluid below the set pressure of the relief valve flows through third delivery means such as flexible transfer line 62 to an inlet 64 on distribution ring 65, as shown in FIGS. 4 and 5. Distribution ring 65 is mounted on and circumscribes compressor crankshaft 12, and as shown in the isolated elevational view in FIG. 5, is provided with an internal annular groove 68 through which lubricating fluid is introduced into the crankshaft for distribution to areas where lubrication is required. An opening 70 in the form of a port on the surface of the crankshaft communicates with groove 68, as best seen in FIG. 4, and effects the continuous delivery of lubricating fluids from the annular groove 68 into port 70 during rotation of crankshaft 12. The lubricating fluid is thereafter transferred by means of positive pressure through fourth delivery means such as passages 72 located within the crankshaft to wear areas where lubrication is required. The lubricating fluid is also transferred through internal passageways to spray nozzle 74, which serves to provide lubricating fluid to the teeth of crankshaft drive gear 45.
The spray nozzle 74 is of a plug design which is well known in the art. The plug is comprised of an externally threaded flange at one end and an angled drilled orifice at the other. A bore runs axially through the nozzle. In operation, the threaded portion of the nozzle is inserted into a threaded female socket in the crankshaft thereby connecting the bore of the spray nozzle 74 and internal fluid passageway 72. The nozzle is preferably rotatably adjustable to provide a continuous spray of lubricating fluid to crankshaft gear 45 as may be seen in FIG. 4. After introduction of the lubricating fluid to the bearing areas of the teeth on gears 45 and 46, the fluid is returned to the crankcase sump (not shown) by gravitational forces.
Those skilled in the art will appreciate that the lubrication system of the present invention can be installed as original equipment on air compressors, or can be retrofit to upgrade the lubrication systems of older compressors. In these latter applications, removal of a portion of a sidewall of the compressor structure, if necessary, not only facilitates installation of the lubrication system, but also creates a port which can then be covered by the inspection plate. Subsequent removal of the inspection plate thus permits easy monitoring and periodic maintenance of the internal components of the compressor and the lubrication system. | In a lubricant delivery system for use in an air compressor having a rotatable crankshaft and an internal chamber accessible by removal of an inspection plate having inner and outer surfaces, a positive displacement fluid pump mounted in the internal chamber and fluid lines for conveying lubricating fluid from the pump to a removable filter mounted on the outer surface of the inspection plate. Pressure relief means are associated with the filter for relieving pressure above a set point, and a distribution ring is adaped to circumscribe the crankshaft for introducing lubricating fluid to the crankshaft and from there to areas where lubrication is required. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a division of U.S. application Ser. No. 10/165,135, filed Jun. 6, 2002 now U.S. Pat. No. 6,914,133 entitled “Human Phosphodiesterase IV Isozymes” which is a division of U.S. application Ser. No. 09/717,953, filed Nov. 21, 2000 now U.S. Pat. No. 6,489,457 which is continuation of Ser. No. 08/472,600 filed Jun. 7, 1995 which has issued as U.S. Pat. No. 6,323,041, which is a continuation of U.S. application Ser. No. 08/432,327 filed May 1, 1995 which is abandoned, which is a continuation of U.S. application Ser. No. 08/075,450, filed Jun. 11, 1993 which is abandoned.
BACKGROUND OF THE INVENTION
This invention relates to novel nucleic acid sequences encoding three novel human phosphodiesterase IV (hPDE IV) isozymes.
Cyclic nucleotide phosphodiesterases (PDE's) are a family of enzymes that catalyze the degradation of cyclic nucleotides. Cyclic nucleotides, particularly cAMP, are important intracellular second messengers, and PDEs are one cellular component that regulates their concentration. In recent years, five PDE enzymes (PDE I–PDE V), as well as many subtypes of these enzymes, have been defined based on substrat affinity and cofactor requirements (Beavo J A and Reifsnyder D H, Trends Pharmacol. Sci. 11:150 [1990]; Beavo J, in: Cyclic Nucleotide Phosphodiesterases: Structure, Regulation and Drug Action . Beavo J and Housley M D (Eds.). Wiley: Chichester, pp. 3–15 [1990]).
Theophylline, a general PDE inhibitor, has been widely used in the treatment of asthma. It has been speculated that selective inhibitors of PDE isozymes and their subtypes (particularly the cAMP-specific PDE IV) will lead to more effective therapy with fewer side effects (for reviews, see Wieshaar RE et al., J. Med. Chem., 28:537 [1985] and Giembycz M A, Biochem. Pharm., 43:2041 [1992], Lowe J A and Cheng J B, Drugs of the Future, 17:799–807 [1992]). However, even PDE IV selective drugs such as rolipram suffer from emetic side effects that limit their use. An even more selective approach is to inhibit individual subtypes of PDE IV, each one of which is expected to have its own tissue distribution. If the PDE IV isozyme responsible for efficacy is different from that causing side effects, an isozyme selective drug could separat therapeutic and side effects. The cloning and expression of the human PDE IVs would greatly aid the discovery of isozyme-selective inhibitors by providing purified isoenzymes to incorporate into drug assays.
Mammalian PDE IV, the homologue of the Drosophila Dunce gene (Chen C N et al., Proc. Nat. Acad. Sci . (USA) 83:9313 [1986]), is known to have four isoforms in the rat (Swinnen J V et al., Proc. Nat. Acad. Sci . (USA) 86:5325 [1989]). The cloning of one human isoform of PDE IV from monocytes was reported in 1990 (Uvi GP et al., Mol. Cell. Bio., 10:2678 [1990]). From Southern blot data, the authors concluded that this enzyme was probably the only PDE IV gene in humans, with the possible exception of one other isozyme. The same group has recently published the sequence of a second human isoform isolated from brain that they designate hPDE IV-B to distinguish it from the monocyte form, which they designate as hPDE IV-A (McLaughlin MM et al., J. Biol. Chem. 268:6470 [1993]). For clarity, we will use this nomenclature as well.
Our invention relates to the nucleic acid sequences encoding three novel human PDE IV isozymes generated by differential splicing from a single gene. We designate these isoforms as hPDE IV-B1, hPDE IV-B2 and hPDE IV-B3. The hPDE IV-B2 sequence encodes a polypeptide nearly identical to that reported for hPDE IV-B (McLaughlin MM et al., J. Biol. Chem. 268:6470 [1993]), and the hPOE IV-B2 splice variant represents the unspliced genomic sequence with respect to the differential splice site. Of the two other splice variants, hPDE IV-B1 encodes the longest polypeptide chain, as well as the N-terminal sequence homologous to its rat homologue, DPD (Colicelli J, et al., Proc. Nat. Acad. Sci . (USA) 86:3599 [1989]).
The novel human PDE IV DNA sequences and their encoded peptides may be used to screen for drugs that are selective for a particular human PDE IV isozyme. Such novel DNA sequences may also be used in assays to detect the presence of a particular POE IV isozyme in human cell lines, thus providing information regarding th tissue distribution of each isozyme and its biological relevance with respect to particular disease states.
The following abbreviations are used throughout this patent:
BAL
bronchoalveolar lavage
bp
base pair(s)
cAMP
cyclic adenosine 3′,5′-monophosphate
dNTP
2′-deoxynucleoside-5′-triphosphate
dATP
2′-deoxyadenosine-5′-triphosphate
dCTP
2′-deoxycytidine-5′-triphosphate
dGTP
2′-deoxyguanidine-5′-triphosphate
dTTP
2′-deoxythymidine-5′-triphosphate
hPDE IV-A
human monocyte PDE IV
hPDE IV-B
human brain PDE IV
hPDE IV-B1
human brain PDE IV, splice variant 1
hPDE IV-B2
human brain PDE IV, splice variant 2
hPDE IV-B3
human brain PDE IV, splice variant 3
kb
kilobase(s)
PCR
polymerase chain reaction
PDE
cyclic nucleotide phosphodiesterase
PDE I
Ca 2+ /Calmodulin-dependent PDE
PDE II
cGMP stimulated PDE
PDE III
cGMP inhibited PDE
PDE IV
high affinity cAMP-specific PDE
PDE V
cGMP specific PDE
RACE
Rapid Amplification of cDNA Ends
RT
avian myeloblastosis virus (AMV) reverse transcriptase
RT-PCR
PCR of RT-transcribed mRNA
SSC
1X SSC = 0.15 M NaCl, 0.015 Na 3 citrate pH 7.0
The nucleotides and amino acids represented in the various sequences contained herein have their usual single letter designations used routinely in the art.
SUMMARY OF THE INVENTION
This invention relates to novel nucleic acid sequences encoding the novel hPDE IV isozymes hPDE IV-B1, hPDE IV-B2 and hPDE IV-B3. More specifically, it relates to DNA segments comprising, respectively, the DNA sequences of SEQUENCE ID NO. 1, SEQUENCE ID NO. 2 and SEQUENCE ID NO. 3, as defined below, or alleleic variations of such sequences. It also relates to polypeptides produced by expression in a host cell into which has been incorporated one of the foregoing DNA sequences or an alleleic variation of such sequence.
This invention also relates to an isolated polypeptide comprising the amino acid sequence of SEQUENCE ID NO. 4, SEQUENCE ID NO. 5 or SEQUENCE ID NO. 6.
This invention also relates to recombinant DNA comprising the DNA sequence of SEQUENCE ID NO. 1, SEQUENCE ID NO. 2 or SEQUENCE ID NO. 3, or an alleleic variations of such sequence.
This invention also relates to an isolated DNA segment comprising the genomic promoter region that regulates transcription or translation of the DNA sequence of SEQUENCE ID NO. 1, SEQUENCE ID NO. 2 or SEQUENCE ID NO. 3, or an alleleic variation of such sequence.
This invention also relates to an assay method for detecting the presence of hPDE IV-B1, hPDE IV-B2 or hPDE IV-B3 in human cells, comprising: (a) performing a reverse transcriptase-polymerase chain reaction on total RNA from such cells using a pair of polymerase chain reaction primers that are specific for, respectively, hPDE IV-B1, hPDE IV-B2 or hPDE IV-B3, as determined from, respectively: (i) the DNA sequence of SEQUENCE ID NO. 1 or an alleleic variation thereof; (ii) th DNA sequence of SEQUENCE ID NO. 2 or an alleleic variation thereof; or (iii) the DNA sequence of SEQUENCE ID NO. 3 or an alleleic variation thereof; and (b) assaying the appearance of an appropriately sized PCR fragment by agarose gel electrophoresis.
This invention also relates to a method of identifying compounds or other substances that inhibit or modify the activity of hPDE IV-B1, hPDE IV-B2 or hPDE IV-B3, comprising measuring the activity of, respectively, hPDE IV-B1, hPDE IV-B2 or hPDE IV-B3, in: (a) a cell line into which has been incorporated recombinant DNA comprising the DNA sequence of SEQUENCE ID NO. 1, SEQUENCE ID NO. 2 or SEQUENCE ID NO. 3, or an alleleic variation thereof, or (b) a cell line that naturally selectively expresses hPDE IV-B1, hPDE IV-B2 or hPDE IV-B3, as determined by the assay method described above.
This invention also relates to an isolated DNA segment comprising a DNA sequence that is a subset of SEQUENCE ID NO. 1, SEQUENCE ID NO. 2 or SEQUENCE ID NO. 3, or an alleleic variation thereof, and that is capable of hybridizing to, respectively, SEQUENCE ID NO. 1, SEQUENCE ID NO. 2 or SEQUENCE ID NO. 3, or an alleleic variation thereof, when used as a probe, or of amplifying all or part of such sequence when used as a polymerase chain reaction primer.
As used herein, the term “functionally equivalent DNA segment” refers to a DNA segment that encodes a polypeptide having an activity that is substantially the same as the activity of the polypeptide encoded by the DNA to which such segment is said to be functionally equivalent.
As used herein, the term “subset of a DNA sequence” refers to a nucleotide sequence that is contained in and represents part, but not all of such DNA sequence, and is sufficient to render it specific to such sequence when used as a PCR primer and to render it capable of hybridizing to such sequence when used as a probe at high stringency.
The term “functionally equivalent polypeptide” refers to a polypeptide that has substantially the same activity as the polypeptide to which it is said to be functionally equivalent.
The term “subset of a polypeptide” refers to a peptide sequence that is contained in and represents part, but not all of such polypeptide.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . hPDE IV-B1, hPDE IV-B2 and hPDE IV-B3 Restriction MaD and Clone Diagram. This figure shows the relationship between the cDNA sequences encoding the three splice variants. Black boxes indicate protein coding regions and open boxes indicate untranslated regions.
FIG. 2 . hPDE IV-B1, hPDE IV-B2 and hPDE IV-B3 DNA and Translated Amino Acid Sequences. (+) Numbering begins with the “A” of the ATG start codon in hPDE IV-B3. Four stop codons are designated by “***”. These include the protein translation stop (1,552), and the stop codons that prevent the coding region from coritinuing further in the 5′ direction in each splice variant: hPDE IV-B1 (−630), hPDE IV-B2 (−270) and hPDE IV-B3 (−89). The alternate splice junction is between nucleotides −23 and −24, and the putative splice acceptor sequence in hPDE IV-B2 (−33 to −24) is underlined.
FIG. 3 . Alternative Splice Junction. This figure is a close-up view of the splice junction between −24 and −23, showing the three aligned sequences hPDE IV-B1, hPDE IV-B2 and hPDE IV-B3. The putative splice acceptor sequence in hPDE IV-B2 (−33 to −24) is underlined.
FIG. 4 . Amino Acid Sequence Comparison: hPDE IV-B1, hPDE IV-B2, hPDE IV-B3, and Rat DPD. Identity with the hPDE IV-B1 sequence is indicated with a dash. A translation of the region upstream of the hPDE IV-B3 start codon is shown in parenthesis to highlight the complete sequence divergence of hPDE IV-B2 and hPDE IV-B3 from hPDE IV-B1 at amino acid 196.
FIG. 5 . Restriction Map of the hPDE IV-B Genomic Locus. Transcriptional orientation (5′–3′) of hPDE IV-B is from left to right, with the approximate positions of exons known by partial sequence analysis indicated by solid boxes (coding). The position of the stop codon is indicated by an asterisk, followed by a segment of a 3′ untranslated region (open box). Regions hybridizing strongly to the 308 bp probe, as described in the text, are indicated by a dark hatched box, while weakly hybridizing regions are shown as lighter hatched regions. It is because of weak hybridization between the EcoRI and HindIII sites in λ11.1 that we position an exon (with a “?”) in that interval. The hybridizing restriction fragments seen in genomic blots with the 308 bp probe are indicated below the figure.
DETAILED DESCRIPTION OF THE INVENTION
The procedures by which the DNA sequences encoding for novel isozymes hPDE IV-B1, hPDE IV-B2 and hPDE IV-B3 were identified and isolated as described below.
Discovery of PDE IV-B Using Degenerate PCR: The degenerate PCR primers (5′-Deg and 3′-Deg, as described below in the section labelled Materials and Methods) were designed against amino acid sequences that were conserved (with one exception) between the six published PDE IV sequences from human, rat, and Drosophila (Uvi GP et al., Mol. Cell. Biol. 10:2678 [1990], Swinnen J V et al., Proc. Nat. Acad. Sci . (USA) 86:5325 [1989], and Chen C N et al., Proc. Nat. Acad. Sci . (USA) 83:9313 [1986]). These primers were expected to amplify 308 bp of PDE IV sequence from any human isoform mRNA that also conserved those amino acids. The RT-PCR was done on human BAL sample total RNA as described below in the section labelled Materials and Methods, and a fragment of the correct size was obtained. Sequence analysis of this fragment showed it to be different from hPDE IV-A (Uvi GR et al., [1990]). This fragment of hPDE IV-B corresponds to bp 1,575 to 1,882 in SEQUENCE ID NO. 1. This fragment was isolated from several independent PCR reactions and sequenced to confirm that no apparent differences were due to PCR artifacts.
Isolation of a cDNA Clone for hPDE IV-B: The human medulla cDNA library was screened as described below in the section labelled in Materials and Methods, and a single cDNA clone was obtained. The insert sequence corresponds to bp 924 to 2,554 of SEQUENCE ID NO. 1, and was clearly not full length in the coding region by comparison with the known PDE IV sequences. Also, since no polyA tract was found at the 3′ end of this clone, we do not believe that the 3′ untranslated region is complete however, this is of no functional significance with respect to producing a hPDE protein. There was one nucleotide difference between the cDNA sequence and the PCR fragment sequence. SEQUENCE ID NO. 1 contains a C at bp 1792, the nucleotide seen in the cDNA sequence, rather than the T that has been seen at this position in PCR isolations. We believe that this difference, which changes an amino acid, is real, and represents an alleleic difference in the human population.
Completion of the cDNA Sequence using the RACE Method: The RACE method showed that there was not just a single 5′ end to the hPDE IV-B cDNA, but at least three. Fragments of different sizes were obtained, all beginning at the GSi oligonucleotide primer site and extending towards the 5′ end of the cDNA. The three fragments that were successfully sequenced had a variable length of non-homologous sequence at the 5′ end that joins the hPDE IV sequence at the same point in all three cases. These different 5′ ends, when joined to the rest of the cDNA sequence, make three forms of the hPDE IV-B gene that we designate hPDE IV-B1 (SEQUENCE ID NO. 1), hPDE IV-B2 (SEQUENCE ID NO. 2), and hPDE IV-B3 (SEQUENCE ID NO. 3). The three hPDE IV-B isoforms make polypeptides of different lengths. From the cDNA sequences, hPDE IV-B1 is predicted to encode a protein of 721 amino acids (SEQUENCE ID NO. 4), hPDE IV-B2 a protein of 564 amino acids (SEQUENCE ID NO. 5), and hPDE IV-B3 a protein of 517 amino acids (SEQUENCE ID NO. 6). The three isoforms are shown diagrammatically in FIG. 1 , and the DNA sequence and amino acid translation of the three isoforms of hPDE IV-B is shown in FIG. 2 .
The most logical explanation for the three hPDE IV-B isoforms is that they are generated by alternative splicing of 5′ exons onto the shared 3′ sequence. The putative alternative splice junction is shown at −23 bp in FIG. 2 . To test this hypothesis, w amplified PCR fragments from human genomic DNA using primers on either side of the putative splice junction. hPDE IV-B1 and hPDE IV-B3 specific 5′ primers did not give amplified fragments, indicating that the sequences on either side of the putative splice lie further than 2 kb apart in genomic DNA (the practical limit for PCR amplification). Primers specific for the hPDE IV-B2 isoform gave the identically sized fragment as predicted from the cDNA (data not shown), indicating that at least with respect to the putative splice junction at −23 bp, this is the unspliced genomic sequence. Indeed, examination of the sequence of hPDE IV-B2 at this location (underlined bp −33 to −24 in FIGS. 2 and 3 ) reveals an excellent match for a splice acceptor sequence (Breathnach R and Chambon P, Ann. Rev. Biochem. 50:349 [1981]).
hPDE IV-B is very similar to one of the known rat isozymes, DPD (Colicelli J, et al., Proc. Nat. Acad. Sci . (USA) 86:3599 [1989]), with 96.3% amino acid identity in the regions that can be aligned, as compared to only a 74.6% identity with hPDE IV-A. However, of the three splice variants, only hPDE IV-B1 continues to have homology to rat DPD 5′ of the putative splice junction ( FIG. 4 ). Indeed, hPDE IV-B1 extends much further 5′ than rat DPD, and the homology between the two continues to the 5′ end of rat DPD. The fact that the hPDE IV-B1 sequence has been conserved in evolution is strong evidence that this sequence is functional and is translated into protein in vivo. We cannot be sure that the other two splice variants are functional in vivo, although the recent paper (McLaughlin MM et al., J. Biol. Chem. 268:6470 [1993]) reporting the hPDE IV-B2 sequence has shown by expression cloning that this isoform can produce enzymatically active protein in a yeast expression system.
Mammalian Expression Clones for hPDE IV-B1, -B2, -B3: The hPDE IV-B1, -B2, -B3 cDNA sequences were subcloned into the mammalian expression vector pcDNA1-amp, a vector that is suitable for transiently expressing these genes in COS cells and that was constructed by replacing the 950 bp NheI fragment of pcDNA1 (Invitrogen) with a 1.2 kb PCR fragment from pUC18 (Sigma) containing the Amp resistance gene. The resulting expression clones are designated pc-hPDE IV-B1, pc-hPDE IV-B2, and pc-hPDE IV-B3. All three clones have been shown to direct the expression of proteins that catalyze the degradation of cAMP when transiently transfected into COS cells.
Genomic Sequences for hPDE IV-B: Overlapping genomic clones define − 26 kb of genomic sequence encoding at least the 3′ half of the hPDE IV-B gene ( FIG. 5 ). Limited DNA sequencing of these genomic clones confirms that the SalI restriction site in clone λK2.1 is contained in an exon, and corresponds to the unique SalI site seen in the cDNA sequence (1,235–1,240 in Sequence ID No. 1). Hybridization data ( FIG. 5 ) defines the orientation of the gene, and confirms the hybridizing fragment sizes seen in genomic Southern blots hybridized at high stringency with the 308 bp PCR fragment (bp 1,575–1,882 in SECUENCE ID NO. 1) from hPDE IV-B: EcoRI-6.6 kb, HindIII-4.4 kb, BamHI-4.2 kb.
Deposits
Three cDNA clones (pc-hPDE IV-B1, pc-hPDE IV-B2, and pc-hPDE IV-B3) ar being deposited with the American Type Culture Collection, Rockville, Md. U.S.A. (ATCC).
Assays
Using the DNA sequence of hPDE IV-B and hPDE IV-A, one could make a larg number of isoenzyme specific PCR primer pairs. We have made and tested the following hPDE IV-B and hPDE IV-A specific primer pairs. The sequences 5′B(5′-CGAAGAAAGTTACAAGTTC-3′) and 3′B(5′-AACCTGGGATTTTTCCACA-3′) are a pair of 19-mer primers that specifically amplify a 245 bp fragment from hPDE IV-8, and the sequences 5′A(5′-CACCTGCATCATGTACATG-3′) and 3′A(5′-TCCCGGTTGTCCTCCAAAG-3′) are 19-mers that amplify an 850 bp fragment specifically from hPDE IV-A. In addition, one skilled in the art could easily design a pair of PCR primers specific for each of the hPDE IV-B splice variants by using the unique 5′ sequences. Using these primers, one can sensitively assay the presence of these isozymes in any tissue from which total RNA can be isolated (e.g., by the method of Chomcynski P and N Sacchi, Anal. Biochem. 162:156 1987) by performing an RT-PCR reaction on such total RNA using the specific primers and then assaying the amount of the appropriately sized DNA PCR product by agarose gel electrophoresis. The RT-PCR conditions are identical to those described in Materials and Methods, except that the thermocycling parameters are as follows: Denature-94° C., 30 sec; Anneal-55° C. 30 sec; Polymerize-72° C., 60. Amplify for at least 30 cycles.
The claimed DNA sequences of this invention can be reproduced by one skilled in the art by either PCR amplification of the coding region using PCR primers designed from the sequences or by obtaining the described cDNA clones from ATCC directly.
Utility of the Invention
A general utility of the novel human PDE IV genes and their encoded peptides is to allow screening for human PDE IV isozyme specific/selective drugs that may b improved therapeutics in the areas of asthma and inflammation. The cloned genes make it possible, by expression cloning methods familiar to those skilled in the art, to produce active, purified isoenzymes that can be used in PDE IV activity assays (e.g., Davis C W, and Daly J W, J. Cyclic Nucleotide Res. 5:65 [1979], Torphy TJ and Cielinski L B, Mol. Pharm. 37:206 [1990]) to measure the potency of inhibitors against individual isoenzymes. This is true both for distinguishing hPDE IV-A and hPDE IV-B selectiv inhibitors and for distinguishing inhibitors selective between hPDE IV-B1, hPDE IV-B2, or hPDE IV-B3. Since the hPDE IV-B splice variants may each have their own tissue distribution and may be pharmacologically separable from each other, it may be valuable to screen for inhibitors specific for individual splice variants.
Genomic sequences are also of utility in the context of drug discovery. It may be valuable to inhibit the mRNA transcription of a particular isoform rather than to inhibit its translated protein. This is particularly true with hPDE IV-B, since the different splice variants may be transcribed from different promoters. There is precedent for multiple promoters directing the transcription of a mouse brain 2′,3′-cyclic-nucleotide 3′ phosphodiesterase (Kurihara T et al., Biochem. Biophys. Res. Comm. 170:1074 [1990]). This invention would provide the means for one skilled in the art to locate multiple promoters. Isolation of genomic clones containing the promoter(s) and the 5′-most exons of hPDE IV-B1, hPDE IV-B2, and hPDE IV-B3 may be accomplished by screening a human genomic library with the unique 5′ sequences. Such promoters could then be linked to a convenient reporter gene such as firefly luciferase (de Wet J R et al., Mol. Cell. Biol. 7:725 [1987]), transfected into a mammalian cell line, and used to screen for agents that inhibit the activity of the promoter of interest while having minimal effect on other promoters.
Another utility of the invention is that the DNA sequences, once known, give the information needed to design assays to specifically detect each isoenzyme or splice variant. Isozyme-specific PCR primer pairs are but one example of an assay that depends completely on the knowledge of the specific DNA sequence of the isozyme or splice variant. Such an assay allows detection of mRNA for the isozyme to access the tissue distribution and biological relevance of each isozyme to a particular disease state. It also allows identification of cell lines that may naturally express only one isozyme—a discovery that might obviate the need to express recombinant genes. If specific hPDE IV isozymes are shown to associated with a particular disease state, the invention would be valuable in the design of diagnostic assays to detect the presence of isozyme mRNA.
Materials and Methods
(a) Cells/Reagents
Cells from a human bronchoalveolar lavage (BAL) were purchased from the Johns Hopkins University (Dr. M. Liu). Human brainstem tissue was purchased from the International Institute for the Advancement of Medicine. Unless noted below, all restriction endonucleases and DNA modifying enzymes were from Boehringer-Mannheim.
(b) Degenerate RT-PCR
Total RNA was isolated from human tissue as previously described (Chomcynski P and Sacchi N, Anal. Biochem. 162:156 [1987]). To prepare an 80 μl reverse transcriptase (RT) reaction, 4 μg total RNA and 4 μg random hexamer primers (Pharmacia/LKB) were heated to 90° C. for 5 min in 60 μl RNase free water. After chilling on ice, the reaction was brought to 80 μl and the following conditions by the addition of concentrated stocks: 1×RT buffer (50 mM Tris pH 8.3, 6 mM magnesium chloride, 40 mM KCl); 1 mM each dATP, dGTP, dCTP, and dTTP; 1 mM dithiothreitol; 25 U/ml RNasin (Promega); and 900 U/ml AMV reverse transcriptase (RT). Incubate at 42 C for 1 hour, then boil for 5 minutes to inactivate the RT.
A 50 μl PCR reaction was set up by using 3.25 μl of the above reaction mix. Final buffer conditions were (including carryover from RT): 10 mM Tris pH 8.3, 50 mM potassium chloride, 1.5 μM magnesium chloride, 10 μg/ml bovine serum albumin, 2.5% (v/v) Formamide, 200 μM each dNTP, 0.5 pmol/μl each degenerate primer (5′-Deg=5′-CAGGATCCAAPACNATGGTNGAPAC-3′,3′-Deg=5′-GCTCTAGATCNGCCCANGTYTCCCA-3′, where N=A, G, C, or T, P=A or G and Y=C or T) and 0.05 U/μl Amplitaq polymerase (Perkin Elmer). Amplification was don in a Perkin Elmer 9600 PCR thermocycler using the following parameters: denature-94° C., 30 sec; anneal-37° C.+0.5° C./cycle, 60 sec+1 sec/cycle; polymerize-72 C, 60 sec. Amplify for 35 cycles.
(c) Library Screening
8×10 5 clones from a commercially available human medulla cDNA library (Clontech # HL 1089a) were screened with an 857 bp DNA fragment containing the entire conserved catalytic domain of hPDE IV-A. This fragment was generated by RT-PCR amplification from the Jurkat T-cell line mRNA using unique primers to amplify bp 573–1430 from the PDE IV-A sequence (Uvi GP, et al., Mol. Cell. Bio., 10:2678 [1990]). The fragment was labeled to a specific activity >5×10 8 cpm/μg, and hybridized und r the following conditions: 6×SSC, 5× Denhardt's Solution (1× Denhardt's=0.02% each of Ficoll, polyvinylpyrrolidone, and bovine serum albumin), 0.1% sodium dodecyl sulfate (SDS), 100 μg/ml yeast tRNA. Probe concentration was 4×10 6 cpm/ml. Filters w r hybridized at 65° C. for >16 hours, and then washed to a final stringency of 1×SSC at 55° C.
1×10 6 clones from a commercially available human genomic library (Clontech #HL1111j) were screened with the 308 bp PCR fragment of hPDE IV-B (bp 1,575 to 1,882 in SEQUENCE ID NO. 1) and the homologous fragment from hPDE IV-A. The screening conditions were as follows: 5×SSC, 5× Denhardts solution (see above), 40% formamide, 0.5% sodium dodecyl sulfate, and 20 μg/ml herring sperm DNA. Probe concentration was 4×10 5 cpm/ml. The filters were hybridized at 42° C. for >16 hours, and then washed to a final stringency of 0.5×SSC at room temperature. A genomic library was also constructed in the vector LambdaGEM12 (Promega) using the XhoI half-site method, and 1×10 6 clones screened under the same hybridization conditions used for the previous genomic library.
(d) DNA Sequencing
All DNA sequencing was done using an ABI model 373A DNA sequencer on DNA fragments cloned into various pGEM vectors (Promega). Sequencing reactions were done using the Taq sequencing method.
(e) RACE Method
The RACE method ( R apid A mplification of c DNA E nds) was adapted from a published method (Frohman MA and Martin GR, In: Technicue—a Journal of Methods in Cell and Molecular Biology , Vol. 1, No. 3, pp. 165–170 [1989]). In order to produce the 5′ end of the cDNA, an RT reaction was performed on human brainstem total RNA as above with the exception that the gene specific RT primer (GS-RT: 5′-GCAAGTTCTGAATTTGT-3′) was at a concentration of 0.1 pmol/μl. The reaction was incubated at 42° C. for 1 hour and then shifted to 52° C. for 30 min. This higher temperature seems to be critical to avoiding a premature truncation product presumably caused by a sequence that AMV RT has difficulty reading through.
After removing buffers using a Centricon 30 filtration device and concentrating in a speedvac, one tails the cDNA with dATP using terminal transferase (TdT) in a 20 μl reaction volume. Final conditions are: 1×TdT buffer (40 mM K-Cacodylate pH 6.8, 0.1 mM dithiothreitol), 0.75 mM CoCl 2 , 0.2 mM dATP, 1,250 U TdT/ml. Incubate 37° C. for 5 min, inactivate TdT at 65° C. 5 min. This reaction is diluted with water to 500 μl and used as a template in a series of nested PCR reactions.
The first PCR amplification (50 ml) uses the same PCR buffer conditions as above, but uses three primers: the Primer/Adaptor (Ro-dT 17 : 5′-AAGCATCCGTCAGCATCGGCAGGACAAC(T 17 )-3′) at 0.2 pmol/μl, the Forward Outside Primer (Ro: 5′-AAGCATCCGTCAGCATC-3′) at 0.5 pmol/μl, and the Gene-Specific Reverse Outside Primer (GSo: 5′-ATGGCAGCCAGGATTTC-3′) at 0.5 pmol/μl. Taq DNA polymerase is only added after denaturing the reaction to 95° C. for 5 min and equilibrating to 72° C. For the first cycle, the annealing step is 10 min at 55° C., and the extension is at 72° C. for 40 min. After that, cycling parameters (PE 9600 machine) ar: Denature 94° C., 30 sec; Anneal 53° C., 30 sec; Polymerize 72° C., 45 sec. Amplify 28 cycles. Dilute this product 20× to serve as template for a second PCR reaction using primers nested just inside those used in the first PCR reaction. This greatly increases the specificity of the final PCR products.
The second 50 μl PCR reaction uses identical buffer conditions to the first, and uses 1 μl of the 20× diluted product from the first PCR reaction as template DNA. The primers are the Forward Inside Primer (Ri: AGCATCGGCAGGACAAC-3′) and Gene-Specific Inside Primer (GSi: 5′-GGTCGACTGGGCTACAT-3′) both at 0.5 pmol/μl. For 12 cycles, the parameters are the same as the final 28 cycles of the previous amplification. The annealing temperature is then raised to 60° C. for another 18 cycles. Products are then analyzed on an agarose gel. They should extend from the GSi primer to the 5′ end of the mRNA(s).
Sequence ID Summary
1. hPDE IV-B1 cDNA sequence. 2,554 bp.
2. hPDE IV-B2 cDNA sequence. 2,246 bp.
3. hPDE IV-B3 cDNA sequence. 2,045 bp.
4. Predicted amino acid sequence of hPDE IV-B1. 721 amino acids.
5. Predicted amino acid sequence of hPDE IV-B2. 564 amino acids.
6. Predicted amino acid sequence of hPDE IV-B3. 517 amino acids. | This invention relates to novel nucleic acid sequences encoding three novel human phosphodiesterase (hPDE IV) isozymes. It also relates to polypeptides encoded by such sequences.
This invention also relates to an assay method for detecting the presence of such novel isozymes in human cells, and to a method of identifying compounds or other substances that inhibit or modify the activity of such isozymes. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to real-time streaming of multimedia content between locations and people.
[0003] 2. Description of the Background Art
[0004] Presently, various social networks exist that allow an exchange of real-time information between people. There are, however, shortcomings involving real-time content streaming involving nodes between locations and people within the social networking framework. A location is not a living entity and therefore requires people to upload content on its behalf. Although the “Facebook” social network allows people to create “Pages” which may correspond to locations, the content that will display under the “Newsfeed” for the “Friends” of the Page will only display the content provided by the Page creator. Additionally, uploads by others will not display in the Newsfeed and that content can only be found by navigating to the page directly. If a person were interested in many locations, then each page would have to be pulled-up and searched for new content.
[0005] Unlike Facebook, the social media “Foursquare” allows anyone to add content to a location without giving content preference to the location's creator. In Foursquare, although any user can add content, this content is not viewable in any feed or stream. If one wanted to see real-time content, then each individual location would need to be searched for new content. Also, Foursquare does not require “friending” of locations to view content.
[0006] A shortcoming found in many location-based social networks involves duplicate locations. Facebook and Foursquare face this challenge since any user can create a location but there is not an efficient way for users to delete locations. In some social networks, locations can be deleted by any user but there is no validation process other than reiterating the deletion request.
[0007] Generally, the disclosure benefits by combining the “Newsfeed” element from Facebook and the non-preference of content similar to Foursquare. Additionally, systems and methods in accordance with the present disclosure do not require any “friending” to view location information. Since anyone can provide content, the invention requires a photo to be added along with comments, as comments can be subjective while a photo is more objective.
[0008] Therefore, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the multimedia streaming art.
[0009] Another object of this invention is to provide a user of any social media site the ability to post multi-media information about a location, which will be viewable by any other user within a real-time photo stream navigable in horizontal and vertical direction.
[0010] Another of this object is that a photo stream will prioritize content by algorithmic and time elements.
[0011] Another object of this invention is to utilize photo tags such as timestamp and GPS coordinates to validate pictures that are uploaded to the stream.
[0012] Another object of this invention is to allow any user to create or delete a venue, while deletions will rely on a new method of validation.
[0013] Another object of this invention is to allow advertisers to create campaigns within the system and pay for the advertisements through in-app purchasing.
[0014] Another object of this invention is to allow advertisers to create campaigns that are geographically targeted to users who are within the set geographic parameters.
[0015] The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
[0016] For the purposes of summarizing this invention, the invention comprises a multi-platform mobile application and website acting as a vehicle for the exchange of location relevant information. Users of the application can post content which includes a photo and a related comment. This content is then viewable by other users in the form of a bi-directional visual stream of the photos with related comments. Users can scroll through this photo stream by navigating horizontally, which will display photos related to different location. By scrolling vertically, users can view all posts related to a single location. Other display mechanisms may also be utilized.
[0017] The invention may solve the problem of finding the newest and most relevant location related content via the real-time photo stream. In a preferred embodiment, since any user can post information, photos are required unlike other applications. Furthermore, people do not search locations for the relevant content as they can simply view and navigate the stream. Other applications may have user-provided content, however this content does not display publically without the user selecting each location independently and looking to see if there is any new content to view.
[0018] Employing a method of user-initiated deletion verified by group inaction solves the problem of duplicated locations. Other applications that allow users to add locations to the application's database face the problem of duplicate locations, i.e. the same location listed many times generally spelled differently. The deletion tag within the invention solves this problem by allowing a deletion tag to be applied to a location by any user of the application and then deletion occurs after a period of time and inactivity for that location.
[0019] The in-app purchasing mechanism available by several of the mobile platform providers is utilized within the application as a revenue stream. Users can customize an advertising campaign that will display at the bottom of the photo stream. Since users are viewing content related to locations, advertisers will benefit by providing content that is also related to locations. Since the advertising content is in-line with the content in the stream, the advertising is less intrusive. Additionally, users can choose a geographic area for the advertisements to display. Only people using the application within the specified geographic area will see the advertisement. Other demographic information is available for targeting within the campaign as well.
[0020] The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
[0022] FIG. 1 is an application flow schematic in accordance with the present disclosure;
[0023] FIGS. 2-30 illustrate various embodiments of numerous screens that may be displayed in accordance with the present disclosure. FIGS. 2-30 illustrate the screens in connection with one preferred embodiment, namely a mobile device.
[0024] FIG. 31 is a flow chart depicting steps for a location editing method in accordance with the present disclosure.
[0025] Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] The invention may preferably be a multi-platform mobile application and website. In a preferred embodiment, databases will store content, which is retrieved via web services and displayed on either a website or on a mobile phone running the application. Since the mobile application will carry all of the features found on the website with additional features and functionality, only the mobile application's features will be listed in this section. The application schematic, with screens and views displayed within the invention, is depicted in FIG. 1 .
[0027] A list of features listed numerically within the attached drawings include:
[0028] Login: Existing users can log into the application or website using a previously created username and password set by the user.
[0029] New user signup: New users can create an account. The new user will be prompted for a unique username and password. A dialogue box will appear notifying the user if a username is already provisioned and requiring the user to select a new username. Additionally, the user will enter an email address and other demographic information such as gender and birthday. Another dialogue box may appear if the user is not of a minimum age to use the application.
[0030] Home screen icons: The user can navigate the application by clicking labeled icons on the main screen.
[0031] New messages: A number will display above the Messages icon denoting the number of unread messages.
[0032] Log out: Users can log out of the application by clicking the Log Out button.
[0033] Change password: Users can change the log in password by clicking the Change password button, which will bring up a new page. On the new page the user must enter the existing password followed by the new password entered twice for validation.
[0034] Terms and conditions: Users can view the terms and conditions for using the application by clicking the button.
[0035] Stream select: Users will have three initial options for viewing the photo stream. Choosing “View places around me” will select locations from a pre-determined radius from the user's GPS location. The other options are “Select an area” and “My favorites.”
[0036] Select an area: A user can input an address and zip code, or simply a zip code, along with a radius to define a geographic area to view locations within the stream.
[0037] My favorites, groups: Sets of locations can be put into groups. Users can edit group names or click a button to view the stream, which will only contain the locations within the group.
[0038] My favorites, locations: Locations can be deleted from a group or moved to another group.
[0039] Location names: Location names are denoted above or below the photo thumbnails within the stream.
[0040] Location images: Photo thumbnails corresponding to locations are displayed in the stream.
[0041] Horizontal scrolling: Users can scroll horizontally between locations by swiping left or right over the location images.
[0042] Photo stack: The first location image in the stream can contain a stack of photos that correspond to that location.
[0043] Vertical scrolling: Users can scroll vertically over the photo stack, which will display the images in the stack.
[0044] Location details: The front photo in the photo stack will have details that display on the screen. These details include the timestamp for when the photo was uploaded, the username of the person who posted the image, and comments added by the posting user.
[0045] Options button: Clicking the options button will bring up a page with filtering options that can be applied to the stream.
[0046] Highlights: Highlights will display at the bottom of the screen below the stream. Highlights are discussed in more detail below.
[0047] Location information: The location name and address will be listed at the top of the screen.
[0048] Add location icon: Clicking the icon will allow the user to add the location to an existing group within the “My favorites” section or create a new group and add the location to the new group.
[0049] Username: The username of the person posting the photo is listed.
[0050] Enlarged image: The picture that displays is an enlarged version of the thumbnail from the stream.
[0051] Helpful buttons: Users can click on “Helpful” or “Not helpful” for any post. This data is collected and used within the sorting algorithm for the stream.
[0052] Report photo: Users can flag a photo as abusive by clicking the button. Flagged images may be deleted from the system.
[0053] Add comment: The user can add a comment to the comment thread.
[0054] Comment thread: Comments posted by other users are listed, in order by most recent first, within the comment thread.
[0055] Sorting options: Users can select between two algorithmic sorting options.
[0056] Keywords: A keyword or keywords can be used to filter the locations displaying within the stream.
[0057] Geography: Users can re-define the geographic area for displaying locations by typing in an address with corresponding radius.
[0058] Age filter: Users can apply an age filter that will only display stream photos that are posted by people that match the age parameters.
[0059] Gender filter: Users can apply a gender filter that will only display stream photos that are posted by people that match the gender parameter.
[0060] Relationship status filter: Users can apply a relationship status filter that will only display stream photos that are posted by people that match the selected status options.
[0061] Interested gender filter: Users can apply an interested gender filter that will only display stream photos that are posted by people that match the interested gender parameter.
[0062] Phone album: The mobile phone's photo album can be accessed to select a photo.
[0063] Access camera: The phone's camera can be accessed to take a picture within the application.
[0064] Crop photo: The selected photo from either the phone's album or a picture taken within the application will display. This photo can be scaled and cropped by using multi-touch.
[0065] Add location: Locations are be added to the database by users. Users will be prompted to enter the location name and address.
[0066] List of locations: A list of locations will populate based on the GPS coordinates of either the tagged photo or the phone's current position. This list will cover a pre-determined radius around the GPS coordinates.
[0067] Delete location: User's can delete a location. See (location editing method) for additional details.
[0068] Image review: The scaled and cropped image is displayed for a final review.
[0069] Photo comment: The user can add a comment related to the photo post.
[0070] Social media post: Users can simultaneously post the photo and comment to additional social media when posting to the application.
[0071] Sign up date: The date the user signed up for the service is displayed.
[0072] Profile pictures: Users can add several photos, which will display under the user's profile. The first photo will serve as the user's primary photo.
[0073] Social media connector: Users will be able to connect to other social media for simultaneous posting.
[0074] Profile information: A user can add information to their profile. This information includes, but is not limited to, gender, birthday, relationship status, interested in (gender), and comments.
[0075] Profile edit: Users can edit photos and profile information at any time.
[0076] Hide information: Users can show or hide profile information from the public.
[0077] Allow messages: Users have the option of allowing messages from other users or not allowing messages.
[0078] Blocked users list: The list of blocked users is listed. These blocked people cannot send messages to the user.
[0079] Block user: Clicking this toggle will block or unblock the person from being able to message the user and will be added to the blocked users list.
[0080] Profile username: The username of the profile being viewed is listed.
[0081] User photos: The thumbnail photos a user chooses to display publically are displayed at the top of the page.
[0082] User information: The profile information a user chooses to display publically is listed.
[0083] Send message: Messages can be sent to the user of the displayed profile if the user has allowed messages and the person sending the message is not on the user's blocked user list.
[0084] Comment photo: The photo from the post will display. Only posts that the user added a comment will display.
[0085] User's comment: Comments will only display in this section if the user had added to the thread. The comment and timestamp is listed.
[0086] Primary photo: The primary photo or a default system icon will display for users that have been messaged.
[0087] Message username: The username of the other user will display.
[0088] Message timestamp: The date and time of the message will display whether the message was sent or received.
[0089] Message text: The truncated message text will display.
[0090] First person username: If the user sent the message then the username will display as “me.”
[0091] Message timestamp: same as 61 .
[0092] Full message: The full message text will display.
[0093] Message username: same as 60
[0094] New message: same as 56 . However if the user has elected to not receive messages from users but has an active message string, then a message can still be sent.
[0095] Search posts: A user can search their past photo posts by either date range or keyword.
[0096] Thumbnail posts: The thumbnail post uploaded by the user is displayed along with the related location name and timestamp.
[0097] Other user thumbnail posts: Photos posted by other users that were uploaded to the same location within a specified timeframe of the user's post will appear on the right side along with the username of the person who posted the photo.
[0098] Delete related posts: The user can delete posts added other users, which will be removed from the archive section. The delete button is found next to each image.
[0099] User's posts vertical scroll: The user can scroll vertically which will scroll through the user's posts and related posts from other users.
[0100] Other users' posts horizontal scroll: The user can scroll horizontally which will scroll through all related photo posts by other users.
[0101] Available funds: A currency amount will be listed at the top denoting the amount of funds available for highlight campaigns.
[0102] Add money: Users can add money to their account through an in-app purchase. The in-app purchase transaction will occur within the mobile platform the person is utilizing. Generally, there will be a credit card on file in which the person will simply enter a password to authorize the financial transaction all within the application.
[0103] Set up new campaign: Clicking this button will allow the user to create a new highlight campaign.
[0104] Existing campaigns: Existing highlight campaigns are listed in which the user can simply scroll through the list and click to open the campaign details.
[0105] Add amount: Icons of various currency amounts are listed on this page. Clicking an icon will enable an in-app purchase for the amount listed on the icon and credit the user's available funds for highlight campaigns.
[0106] Toggle highlight activation: Highlights can be activated or inactivated by a toggle button.
[0107] Delete highlight campaign: Campaigns can be deleted by clicking the button.
[0108] Campaign name: The name of the highlight campaign is listed and the user at any point can edit that name.
[0109] Campaign statistics: Statistics related to an active highlight campaign are available to the user. The statistics include, but are not limited to, the amount of money spent, remaining money, and total views.
[0110] Total spend: The user can designate a ceiling limit for monetary spend within each individual highlight campaign.
[0111] Campaign times: The user can specify when a campaign will begin and end based on set days and times.
[0112] Recurring campaign: The user can have the campaign recur for each day, each week, or day of the month.
[0113] Alias: Users can set a website alias to display instead of the user's username.
[0114] Demographic filters: Various filters can be used to target the highlight campaign. All profile information elements can be used for targeting purposes.
[0115] Campaign area: A geographic area for displaying the highlight can be set. Only users within this area using the application will be able to see the highlight.
[0116] Highlight photo: The photo used for the campaign can be viewed or edited.
[0117] Highlight message: The text associated with the highlight can be viewed or edited.
[0118] Alias verification: For verification purposes the user will enter an email address associated with the website domain they wish to use as the alias. The system will then send an automated email to the email address for verification. Once verified the web address will display on the highlight.
[0119] Radius options: The highlight campaign can utilize a radius around a fixed address or from the GPS coordinates of the phone of the highlight creator's mobile phone.
[0120] No highlight photo: The user can create a text-only highlight.
[0121] Save and activate: The user can review the highlight as it will display on other user's screens. Clicking the button will initialize the campaign.
[0122] Help search: Words or phrases can be used to search help topics.
[0123] Help tutorials: Video and pictorial tutorials can be browsed.
[0124] The location editing method (See FIG. 31 ) may utilize the following steps and rules:
[0125] Step 1) User selects button to delete a location.
[0126] Step 2) User is prompted for a disposition reason for the deletion, such as duplicate, out of business, incorrect venue information etc.
[0127] Step 3) The user will be prompted a final time to delete location. If the user confirms then the location will be tagged for deletion.
[0128] Locations tagged for deletion will follow the following rules:
[0129] Rule 1: The location will move down in the priority order on the list of locations that displays. For example, it may move down 15 slots in the list.
[0130] Rule 2: If a specified number of users upload to the location tagged for deletion within a specified timeframe, then the location's deletion tag is removed and it goes back into the original priority order.
[0131] Rule 3: If a location tagged for deletion does not get the specified number of users to upload to it within the specified timeframe, then the location is deleted from the system.
[0132] This methodology is utilizing inaction by users as a confirmation to the action as opposed to requiring action by others to confirm the deletion. Since users can create and delete venues, any editing of location information is handled by deletion of the current venue and then addition of the location with the corrected information.
[0133] Another benefit of the present disclosure may be Highlights. A person can select from various demographic elements and specify a geographic area for their ad to display. For example, Jan owns a wedding shop in downtown St Pete and has a sale on wedding dresses. She wants to get people to her store and so she sets up a Highlight campaign in Eyecrawler. She chooses a radius of half-a-mile around her store's address and additionally uses some demographic elements such as gender: female and relationship status: engaged. This means that ONLY engaged women using Eyecrawler within half-a-mile of the store's address will see the Highlight.
[0134] Highlights will rotate only when the stream is refreshed. This means that the same highlight ad will display on the screen as a person navigates through the photo stream. Essentially the system will run a query whenever the stream comes up or is refreshed. This query will identify the user's GPS coordinates and will pull a list of potential Highlights that meet the geographic and demographic criteria. Out of that potential list of Highlights one will display at random.
[0135] Highlights can consist of a picture with text or text alone.
[0136] The purchasing mechanism for Highlights is an in-app purchase. This means that a person doesn't have to put in any credit card information as their mobile platform e.g. The App Store for Apple or Android Market for Android etc. will already have their card on file. The person simply puts in their password and the card on file is billed.
[0137] A person can create multiple Highlight campaigns and designate when each one will be active. The system may also give recurring options so a person can create a Highlight and have it display every Wednesday for example. Once funds run out a user will need to buy more credits. If they are out of credits all active campaigns will suspend and the user will get a notification that their account is out of funds at which point they just repeat the in-app purchase described above.
[0138] The Highlights campaign can be further described in a preferred embodiment as follows. An advertiser creates the campaign, preferably via a smartphone or other mobile device. The advertiser may specify various parameters, such as demographics (age, gender, relationship status, etc.) to whom the advertisement should be directed. Because the system is designed in a preferred embodiment for mobile devices which are typically associated with a single person, a system in accordance with the present disclosure can specifically target a variety of demographic groups.
[0139] The advertiser may also select a geographic area in which the campaign is to be displayed. In a preferred embodiment, the advertiser selects an address or other geo-location information, and a radius around which the campaign should be active. This information may then preferably be stored in a server to be utilized for the system and method disclosed herein. Preferably, the information is stored in a database.
[0140] A user of the system and method will preferably access a stream on their mobile device. While the stream is loading, the mobile device may preferably send its geographic information to the server. This geographic information is preferably latitude and longitude coordinates, but any geographic or geo-locating information may be utilized. The server then queries its database to determine if the coordinates provided fall within the coordinates of any active Highlights campaigns. If so, the server further checks the user's demographic information to see if they match the demographic information associated with the campaign. In a preferred embodiment, the user has provided his or her demographic information in an initial or previous use of the mobile device so that the demographic information may be stored in the database. Alternatively, the mobile device may also communicate sufficient demographic information gathered from the mobile device when it communicates location information to the server. If there is a match for both location and demographics, the respective advertising campaign will be displayed. If there are multiple matches, a random campaign may display, or the campaigns may display sequentially.
[0141] Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
[0142] Now that the invention has been described, | A system and method for preparing an advertising campaign, the campaign prepared on a first mobile device and directed to a demographic group within a location. The campaign is then received by a second mobile device associated with the demographic group when the second mobile device is located within the location. The system can be accessed through a website or through mobile platform applications. Certain content can only be added through a mobile device in which GPS data and photo time stamping will be accessed. Real-time content will be viewable by users in the form of a two-directional stream of photos with related comments in which this content is prioritized by time and algorithmic methods. Users will have the ability to communicate with other users through the system while advertising can be set up in the mobile application with payment occurring through an in-app purchasing mechanism. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 61/075,548, filed Jun. 25, 2008, the entire disclosure of which is incorporated by reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to a surgical access apparatus for positioning within an incision in tissue. More particularly, the present disclosure relates to a surgical access apparatus that is adapted to removably receive one or more surgical objects, and configured for insertion into, and anchoring within, the incision.
[0004] 2. Background of the Related Art
[0005] Today, many surgical procedures are performed through small incisions in the skin, as compared to the larger incisions typically required in traditional procedures, in an effort to reduce both trauma to the patient and recovery time. Generally, such procedures are referred to as “endoscopic”, unless performed on the patient's abdomen, in which case the procedure is referred to as “laparoscopic”. Throughout the present disclosure, the term “minimally invasive” should be understood to encompass both endoscopic and laparoscopic procedures.
[0006] In general, during a minimally invasive procedure, a surgical access apparatus or portal member is used to facilitate access to the surgical site with surgical instrumentation, e.g., endoscopes, obturators, staplers, and the like. A typical surgical access apparatus defines a passageway or lumen through which the surgical instrumentation is inserted and the procedure is carried out.
[0007] While many varieties of surgical access apparatus are known in the art, a continuing need exists for a surgical access apparatus that may be releasably and reliably secured within the patient's tissue throughout the duration of the minimally invasive procedure.
SUMMARY
[0008] The present disclosure relates to a surgical apparatus for positioning within an incision in tissue. In one aspect of the present disclosure, the surgical access apparatus includes an elongated seal member defining a longitudinal axis and a deployment member.
[0009] The elongated seal member is adapted to transition between first and second conditions. In the first condition, the elongated seal member defines a first transverse dimension sufficient to facilitate securement of the elongated seal member within the incision and a tissue engaging portion configured to engage the tissue in substantially sealed relation. In the second condition, the elongated seal member defines a second transverse dimension, which is less than the first transverse dimension, to facilitate insertion of the elongated seal member within the incision.
[0010] The elongated seal member is at least partially composed of an at least semi-resilient material such that the elongated seal member is biased towards the first condition thereof. The elongated seal member includes a longitudinal passageway for the reception and passage of a surgical object in substantially sealed relation.
[0011] The elongated seal member includes a proximal end, which may include a stiffening member, and a distal end, which may include a lip. The stiffening member is adapted to facilitate anchoring of the elongated seal member within the incision, and in one embodiment thereof, may be generally annular in shape. The lip extends outwardly relative to the longitudinal axis, when the elongated seal member is in the first condition, and is dimensioned to engage the tissue to resist removal of the elongated seal member therefrom.
[0012] In one embodiment, the elongated seal member defines an internal cavity that is configured to retain a fluid therein, and in another embodiment, the elongated seal member defines a variable cross-sectional dimension along the longitudinal axis.
[0013] The deployment member of the surgical access apparatus is at least partially positionable within the longitudinal passageway of the elongated seal member. The deployment member is secured to the elongated seal member along an internal surface thereof such that distal longitudinal movement of the deployment member along the longitudinal axis causes the elongated seal member to transition from the first condition to the second condition. When subjected to a predetermined force, the deployment member may be detached from the elongated seal member to permit the deployment member to be removed from the longitudinal passageway with the elongated seal member in the first condition, thereby leaving the elongated seal member within the incision to receive the surgical object. The deployment member may be releasably secured to the elongated seal member with an adhesive.
[0014] In one embodiment, the deployment member includes a sleeve having an opening to receive at least one digit of a user to thereby facilitate grasping and removal of the deployment member from the elongated seal member.
[0015] In another aspect of the present disclosure, the surgical access apparatus includes a housing configured to removably receive at least one surgical object, an elongated member extending distally from the housing, and at least one filament secured to the elongated member and extending proximally relative thereto.
[0016] The housing includes locking structure configured to engage the at least one filament and thereby maintain the second condition of the elongated member. The locking structure includes at least one channel formed in the housing that is configured to at least partially receive the at least one filament. In one embodiment, the locking structure may include a locking member that is repositionable between unlocked and locked positions. In this embodiment, the locking member defines a channel therethrough that is configured to at least partially receive the at least one filament. In the unlocked position, the channel of the locking member and the channel formed in the housing are substantially aligned, and in the locked position, the channel of the locking member and the channel formed in the housing are substantially misaligned. The locking member may be biased towards the locked position by a biasing member.
[0017] The elongated member includes a tubular braid defining an axial lumen that is configured to allow the at least one surgical object to pass therethrough. The braid is formed of a mesh of fibers which may be either substantially elastic, or substantially inelastic.
[0018] The elongated member is adapted to transition from a first condition, in which the elongated member is configured for at least partial insertion within the incision, and a second condition, in which the elongated member defines a tissue engaging portion configured to facilitate anchoring of the elongated member within the patient's tissue.
[0019] The filament, or filaments, are dimensioned for grasping by a user such that drawing the at least one filament proximally transitions the elongated member from the first condition to the second condition. The filament, or filaments, may be disposed within the lumen of the elongated member, or externally thereof. The filament, or filaments, may alternatively be secured to an intermediate or distal portion of the elongated member.
[0020] In one embodiment, the surgical access apparatus further includes a membrane disposed about at least a proximal portion of the elongated member to facilitate anchoring of the elongated member within the tissue. The membrane may also facilitate passage of the at least one surgical object through the elongated member.
[0021] In another aspect of the present disclosure, a method of percutaneously accessing an underlying surgical work site is disclosed. The first step of the method includes providing a surgical access apparatus having an elongated seal member and a deployment member.
[0022] The elongated seal member defines a longitudinal axis, a proximal end, and a distal end. The elongated seal member has a longitudinal passageway for reception and passage of a surgical object and is adapted to transition between a first condition and a second condition. In the first condition, the elongated seal member defines a first transverse dimension, and in the second condition, the elongated seal member defines a second transverse dimension. The elongated seal member comprises an at least a semi-resilient material to be normally biased towards the first condition thereof.
[0023] The deployment member is at least partially positionable within the longitudinal passageway of the elongated seal member and is secured to the elongated seal member along an internal surface adjacent the distal end thereof. Upon distal longitudinal movement of the deployment member along the longitudinal axis, the elongated seal member is caused to transition from the first condition to the second condition.
[0024] The deployment member is advanced distally within the longitudinal passageway of the elongated seal member to thereby transition the elongated seal member into the second condition, and secure the elongated seal member within the incision. Subsequently, the surgical access apparatus is inserted into the incision, the deployment member is removed from the elongated seal member, and the surgical object is inserted into the longitudinal passageway and used to perform at least one surgical function. Thereafter, the surgical object is removed from the longitudinal passageway, the elongated seal member is removed from the incision, and the incision is closed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Various embodiments of the present disclosure are described hereinbelow with references to the drawings, wherein:
[0026] FIG. 1 is a perspective view of a surgical access apparatus including a seal member and a sleeve member in accordance with one aspect of the present disclosure.
[0027] FIG. 2A is a side cross-sectional view of the seal member of FIG. 1 shown in a first condition with the sleeve member removed therefrom.
[0028] FIG. 2B is a side cross-sectional view of the seal member of FIG. 1 shown in a first condition with the sleeve member inserted therein and secured thereto.
[0029] FIG. 3 is a side cross-sectional view of the seal member of FIG. 1 inserted into an incision in tissue and shown in a first condition with a surgical object extending therethrough.
[0030] FIG. 4 is a side cross-sectional view of the seal member of FIG. 1 shown in a second condition with the sleeve member inserted therein and secured thereto.
[0031] FIG. 5 is a side cross-sectional view of one embodiment of the seal member of FIG. 1 incorporating a fluid disposed within an internal cavity.
[0032] FIG. 6 is a side cross-sectional view of a surgical access apparatus including a housing, an elongate member, shown in a first condition, and filaments in accordance with another aspect of the present disclosure.
[0033] FIG. 7 is a side cross-sectional view of the surgical access apparatus of FIG. 6 with the elongate member shown in a second condition and inserted into an incision in a patient's tissue.
[0034] FIG. 8 is a side cross-sectional view of one embodiment of the surgical access apparatus of FIG. 6 with the filaments disposed externally of the elongate member.
[0035] FIG. 9A is a side cross-sectional view of one embodiment of locking structure for use with the surgical access apparatus of FIG. 6 shown in a locked condition.
[0036] FIG. 9B is a side cross-sectional view of the locking structure of FIG. 9A shown in an open condition.
[0037] FIGS. 10A-10B are side cross-sectional views of another embodiment of the surgical access apparatus of FIG. 6 including a membrane disposed about the elongate member, the elongate member being respectively shown in its first and second conditions.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0038] In the drawings and in the description which follows, in which like references numerals identify similar or identical elements, the term “proximal” will refer to the end of the apparatus which is closest to the user during use, while the term “distal” will refer to the end which is furthest from the user. Additionally, the term “incision” should be understood as referring to any opening in a patient's tissue, whether formed by the user or pre-existing.
[0039] With reference to FIGS. 1A-3 , a surgical access apparatus 10 is disclosed that is removably positionable within a percutaneous incision 12 formed in a patient's tissue “T” during the course of a surgical procedure, e.g., a minimally invasive procedure, to facilitate access to a patient's underlying cavities, tissues, organs, and the like with one or more surgical objects “I” ( FIG. 3 ). In one aspect of the present disclosure, surgical access apparatus 10 includes a deployment member 100 that is releasably secured to an elongated seal member 200 .
[0040] Deployment member 100 is secured to an internal surface 210 of elongated seal member 200 such that at least a portion of deployment member 100 extends proximally of elongated seal member 200 . Deployment member 100 may be secured to internal surface 210 through any means suitable for the intended purpose of allowing deployment member 100 to be detached from elongated seal member 200 at the election of the user, including but not being limited to the use of a biocompatible adhesive. In one embodiment, as seen in FIGS. 1A-3 , deployment member 100 is configured as a sleeve defining an opening 102 that extends at least partially therethrough. Opening 102 is configured to facilitate grasping of deployment member 100 by a user, e.g., by placing one or more digits therein.
[0041] Elongated seal member 200 includes a proximal portion 202 , an intermediate portion 204 , a distal portion 206 , and a passageway 208 defined by internal surface 210 and extending longitudinally through elongated seal member 200 along a longitudinal axis “A”.
[0042] Proximal portion 202 includes a proximal surface 212 extending outwardly with respect to the longitudinal axis “A” along a transverse axis “B”, and defines a first dimension D 1 . In one embodiment, as seen in FIGS. 1-3 , proximal surface 212 may include at least one stiffening member 214 . Stiffening member 214 may extend distally from proximal portion 202 and at least partially into intermediate portion 204 , as depicted. Alternatively, stiffening member 214 may be substantially annular in configuration and disposed solely within proximal portion 202 . Stiffening member 214 may be formed of any biocompatible material suitable for the intended purpose of rigidifying elongated seal member 200 to facilitate the anchoring thereof within tissue, as discussed below.
[0043] Intermediate portion 204 extends distally from proximal portion 202 . Intermediate portion 204 and defines a second dimension D 2 along transverse axis “B” and a length “L”. The second dimension D 2 of intermediate portion 204 may be either substantially constant along its length “L”, or variable.
[0044] Distal portion 206 includes a lip 216 extending in transverse relation to the longitudinal axis “A”, along axis “B”, and defines a third dimension D 3 . Lip 216 is configured to engage tissue “T” ( FIG. 3 ) when elongated seal member 200 is disposed within percutaneous incision 12 , and thereby resist the removal of elongated seal member 200 .
[0045] The respective first and third dimensions D 1 , D 3 of proximal and distal portions 202 , 206 are each greater than the second dimension D 2 of intermediate portion 204 such that elongated seal member 200 defines an “hour-glass” shape or configuration to assist in anchoring elongated seal member 200 within tissue “T” ( FIG. 3 ). However, an embodiment in which the second dimension D 2 of intermediate portion 204 is substantially equivalent to the respective dimensions D 1 , D 3 of proximal and distal portions 202 , 206 is also within the scope of the present disclosure. Additionally, the third dimension D 3 of distal portion 206 may be appreciably smaller than the first dimension D 1 of proximal portion 202 , as shown in FIGS. 1-3 , or alternatively, the respective first and third dimensions D 1 , D 3 of proximal and distal portions 202 , 206 may be substantially equal.
[0046] The outermost surfaces of proximal and distal portions 202 , 206 are substantially planar in configuration. However, an embodiment is also contemplated herein in which either or both of proximal and distal surfaces 202 , 206 , respectively, define surfaces that are substantially arcuate to facilitate the insertion of elongated seal member 200 within incision 12 .
[0047] Passageway 208 is configured to removably receive surgical object “I” ( FIG. 3 ), as discussed in further detail below. Passageway 208 defines an inner dimension “D P ” that is smaller than the outer dimension “D I ” of surgical object “I” such that the introduction of surgical object “I” to elongated seal member 200 causes passageway 208 to expand or enlarge outwardly with respect to the longitudinal axis “A” along transverse axis “B”. Although the outer dimension “D I ” of surgical object “I” will generally lay within the range of about 3 mm to about 15 mm, the employ of surgical objects have substantially larger or smaller outer dimensions is also within the scope of the present disclosure.
[0048] Referring now to FIG. 4 as well, elongated seal member 200 is adapted to transition from a first (or normal) condition ( FIGS. 1-3 ) to a second (or extended) condition ( FIG. 4 ). In the first condition, seal member 200 defines an overall length “L 1 ”, and the dimension D 2 of intermediate portion 204 is greater than that of the incision 12 to thereby facilitate the anchoring of elongated seal member 200 , as discussed in further detail below. To further assist in the anchoring of elongated seal member 200 , intermediate portion 204 exhibits a substantially irregular profile in the first condition in which a plurality of tissue engaging surfaces 218 are defined. The contact between tissue engaging surfaces 218 and tissue “T” may also form a substantially fluid-tight seal therebetween. When in the first condition, lip 216 extends outwardly along transverse axis “B” to further facilitate the anchoring of elongated seal member 200 within tissue “T” and resist the removal of seal member 200 therefrom. In the second condition, elongated seal member 200 defines an overall length “L 2 ” that is greater than the length “L 1 ” of the elongated seal member 200 when in the first condition, and intermediate portion 204 exhibits a profile that is substantially more uniform, in that tissue engaging surfaces 218 are substantially less prominent. Additionally, when in the second condition, lip 216 extends generally in the distal direction so as not to inhibit the insertion of elongated seal member 200 within incision 12 .
[0049] To facilitate the transition of elongated seal member 200 from the first condition to the second condition, the user grasps deployment member 100 and applies a force “F” thereto that is directed distally, thereby advancing deployment member 100 in that direction. As deployment member 100 is advanced, the engagement between deployment member 100 and internal surface 210 causes intermediate portion 204 to elongate, and lip 216 to deflect, in the distal direction. It should be noted that the elongation of elongated seal member 200 during the transition thereof from the first condition to the second condition may cause portions of elongated seal member 200 , e.g., intermediate and distal portions 202 , 206 , respectively, to deform inwardly along transverse axis “B”, thereby reducing the dimensions of elongated seal member 200 , e.g., the respective dimensions D 2 , D 3 of intermediate and distal portions 202 , 206 , and further facilitating the insertion of elongated seal member 200 within incision 12 .
[0050] Elongated seal member 200 may be formed of any suitable biocompatible material that is at least semi-elastic and deformable in nature, e.g., silicon or memory foam. Forming elongated seal member 200 of an elastic material allows elongated seal member 200 to resiliently transition between the first and second conditions thereof, and acts to return elongated seal member 200 to its first condition upon the removal of force “F” from deployment member 100 . Forming elongated seal member 200 of a material that is also deformable in nature allows intermediate portion 204 to conform to both the smaller dimensions of incision 12 upon the insertion of elongated seal member 200 therein, and permits passageway 208 to accommodate the larger dimensions of surgical object “I”.
[0051] Referring to FIG. 5 , in one embodiment, the resiliency and deformability of elongated seal member 200 is achieved through the incorporation of one or more fluids 220 . Fluid 220 is retained within an internally defined cavity 222 . In this embodiment, fluid 220 may be any suitable biocompatible fluid, including but not being limited to air, water, or saline.
[0052] With respect now to FIGS. 1-4 , the use and function of elongated seal member 200 during the course of a typical minimally invasive procedure will be discussed. Initially, the peritoneal cavity (not shown) may be insufflated with a suitable biocompatible gas such as, e.g., CO 2 gas, such that the cavity wall is raised and lifted away from the internal organs and tissue housed therein, providing greater access thereto. The insufflation may be performed with an insufflation needle or similar device, as is conventional in the art. It should be noted that the present disclosure also contemplates the employ of surgical access apparatus 10 during the course of a procedure in which insufflation is not required or utilized.
[0053] Either prior or subsequent to insufflation, incision 12 is created in the patient's tissue “T”. The dimensions of incision 12 may be varied dependent upon the nature of the procedure. However, when surgical apparatus 10 is employed during the course of procedure performed in an insufflated workspace, for reasons explained just below, it is particularly desirable to incise the tissue “T” so as to create an incision 12 defining dimensions smaller than those defined by intermediate portion 204 when elongated seal member 200 is in its first condition.
[0054] Prior to its insertion, elongated seal member 200 is in its first condition. In the first condition, the dimensions of elongated seal member 200 , e.g., the respective dimensions D 2 , D 3 of the intermediate and distal portions 202 , 206 , may prohibit the insertion of elongated seal member 200 into incision 12 . To allow for the insertion of elongated seal member 200 , the user applies a force “F” to deployment member 100 , advancing deployment member 100 distally and transitioning elongated seal member 200 into its second condition. In the second condition, elongated seal member 200 is subject to a proximally directed biasing force “F B ” that is created by virtue of the resilient nature of the material comprising elongated seal member 200 . Biasing force “F B ” resists the influence of force “F” and is exerted upon deployment member 100 through the association between deployment member 100 and elongated seal member 200 . Upon transitioning into the second condition, elongated seal member 200 is inserted into incision 12 and force “F” is removed from deployment member 100 . Upon the removal of force “F”, biasing force “F B ” returns elongated seal member 200 to its first condition, thereby urging deployment member 100 proximally. After being restored to its first condition, tissue engaging surfaces 218 engage tissue “T” to thereby assist in securing elongated seal member 200 within the patient's tissue “T”. The user may then disengage deployment member 100 from internal surface 210 of passageway 208 by applying a predetermined force thereto, e.g., by pulling or drawing deployment member 100 proximally. Subsequently, the user may introduce one or more surgical objects “I” into passageway 208 such that the minimally invasive procedure may be carried out through apparatus 10 .
[0055] As indicated above, the deformable nature of the material comprising elongated seal member 200 allows intermediate portion 204 to conform to the smaller dimensions of incision 12 in addition to allowing passageway 208 to expand and accommodate the larger dimensions of surgical object “I”. Accordingly, elongated seal member 200 may create substantially fluid-tight seals with both tissue “T” and surgical object “I”, thereby substantially preventing the escape of insufflation gas, if any, and facilitating the secure anchoring of elongated seal member 200 within tissue “T” throughout the course of the procedure.
[0056] After completing the procedure and withdrawing surgical object “I”, elongated seal member 200 may be removed from incision 12 . It should be noted that the material comprising elongated seal member 200 allows for the deformation thereof during its withdrawal from incision 12 to thereby avoid any unnecessary trauma to the patient's tissue “T”. Thereafter, incision 12 may be closed.
[0057] Referring now to FIGS. 6-7 , in an alternate aspect of the present disclosure, surgical access apparatus 10 includes a housing 300 , an elongated member 400 extending distally from housing 300 , and one or more filaments 500 that are secured to the elongated member 400 .
[0058] Housing 300 defines a longitudinal axis “A” and may be fabricated from any suitable biocompatible material including moldable polymeric materials, stainless steel, titanium or the like. Housing 300 is configured for manual engagement by a user and includes an opening (not shown) extending therethrough that is configured for the reception and passage of a surgical object “I”. Housing 300 includes an outer wall 302 which defines a flange 304 having a distal surface 306 and may, optionally, include an internal seal or valve (not shown), such as a duck-bill or zero-closure valve, adapted to close in the absence of surgical object “I”. Examples of such an internal seal or valve may be seen in commonly assigned U.S. Pat. No. 5,820,600 to Carlson, et al. and U.S. Pat. No. 6,702,787 to Racenet et al., which issued Oct. 13, 1998 and Mar. 9, 2004, respectively, the entire contents of which are incorporated by reference herein. Housing 300 further includes locking structure 308 , which is discussed in further detail below.
[0059] Elongated member 400 defines an axial lumen 402 that extends therethrough, along longitudinal axis “A”. Lumen 402 is configured for the reception and passage of a surgical object “I”. Elongated member 400 is configured as a braid 404 formed of a mesh of biocompatible fibers 406 . In one embodiment of elongated member 400 , fibers 406 may be formed of a substantially elastic material such that elongated member 400 may expand along an axis “B” that is transverse, e.g., orthogonal, in relation to longitudinal axis “A”. However, in an alternate embodiment, fibers 406 may be formed of a substantially inelastic material, e.g., polyamide fiber, stainless steel, or the like, such that elongated member 400 experiences a measure of shortening along longitudinal axis “A” upon the introduction of surgical object “I”, further details of which may be obtained through reference to U.S. Pat. No. 5,431,676 to Dubrul et al., the entire contents of which are incorporated by reference herein. The braid 404 may be comprised of fibers 406 having any suitable configuration, including but not being limited to round, flat, ribbon-like, or square.
[0060] Filaments 500 have proximal ends 502 that extend proximally beyond housing 300 and distal ends 504 that are secured to elongated member 400 at attachment points 506 . Attachment points 506 may be located at any suitable position along elongated member 400 proximal of a distal-most end 408 thereof, e.g., at a proximal section 410 , an intermediate section 412 , or a distal section 414 . As seen in FIGS. 6-7 , in one embodiment, filaments 500 are disposed within lumen 402 of elongated member 400 , whereas in an alternate embodiment, filaments 500 are disposed externally of elongated member 400 , as seen in FIG. 8 . In yet another embodiment, filaments 500 may be interlaced within the mesh comprising the elongated member 400 . Filaments 500 may be secured to elongated member 400 at attachment points 506 through any suitable means, such as adhesives. Alternatively, filaments 500 may be integrally formed with elongated member 400 such that filaments 500 constitute proximal extensions of fibers 406 . Filaments 500 are used to facilitate the transition of elongated member 400 from a first (or initial) condition ( FIG. 6 ) to a second (or activated) condition ( FIG. 7 ).
[0061] In the first condition, elongated member 400 defines an initial length “L 1 ” and an initial outer dimension “D 1 ”. Length “L 1 ” may vary depending on the intended usage for apparatus 10 , but in general, “L 1 ” will lie substantially within the range of about 10 cm to about 25 cm, although elongate members 400 that are substantially longer or shorter are also contemplated herein. The initial outer dimension “D 1 ” of elongate member is smaller than the dimensions of incision 12 such that elongated member 400 may be inserted and advanced distally through incision 12 will little or no resistance.
[0062] Upon the application of a force “F” to filaments 500 in the direction of arrow “B”, e.g., by pulling or drawing filaments 500 proximally, elongated member 400 is shortened along the longitudinal axis “A”, thereby transitioning into the second condition. In the second condition, elongated member 400 defines a length “L 2 ” that is appreciably less than its initial length “L 1 ”. Additionally, in the second condition, elongated member 400 defines a tissue engaging portion 416 having an outer dimension “D 2 ” that is appreciably greater than the outer dimension “D 1 ” of the elongated member 400 in the first condition. Tissue engaging portion 416 contacts the patient's tissue “T” about incision 12 and, in conjunction with flange 304 of housing 300 , facilitates the anchoring of apparatus 10 . Additionally, tissue engaging portion 416 acts to at least partially form a seal with tissue “T”.
[0063] As previously indicated, housing 300 of apparatus 10 includes locking structure 308 . Locking structure 308 acts to maintain elongated member 400 in the second condition thereof. As seen in FIGS. 5-6 , in one embodiment, locking structure 308 includes one or more channels 310 formed in housing 300 and one or more engagement members 312 . Channels 310 extend at least partially through housing 300 and have an egress 314 formed either in a proximal-most surface 316 or outer wall 302 of housing 300 . In this embodiment, filaments 500 extend through channels 310 such that the proximal ends 502 thereof may be grasped by the user to thereby transition elongated member 400 into the shortened condition thereof. To maintain elongated member 400 in the second condition, the proximal ends 502 of filaments 500 are secured about engagement members 312 , e.g., by tying. Engagement members 312 may be any structure suitable for the intended purpose of releasably receiving filaments 500 , such as a hook.
[0064] As seen in FIGS. 9A-9B , in an alternate embodiment, locking structure 308 includes channels 310 and a locking mechanism 318 . Locking mechanism 318 includes a locking member 320 having an aperture 322 formed therein, a handle portion 324 , and a biasing member 326 . Aperture 322 is configured to receive filaments 500 and handle portion 324 is configured for manual engagement by the user to facilitate the transition of locking mechanism 318 between a locked condition ( FIG. 9A ) and an open condition ( FIG. 9B ). In the locked condition, aperture 322 is in misalignment with channel 310 such that a portion 508 of filament 500 is disposed between the housing 300 and the locking member 320 , effectively prohibiting any movement of filaments 500 and thereby maintaining the second condition of elongated member 400 . When locking mechanism 318 is in the open condition, however, at least a portion of aperture 322 is aligned with channel 310 such that filament 500 may freely extend therethrough. Biasing member 326 urges locking mechanism 318 towards the locked condition and may be comprised of any structure or mechanism suitable for this intended purpose, e.g., a spring.
[0065] In alternative embodiments, locking mechanism 318 may comprise a single locking member 320 and a single biasing member, or a plurality of locking members engagable with one or more biasing members 326 .
[0066] Referring again to FIGS. 6-7 , the use and function of seal member apparatus 10 will be discussed during the course of a typical minimally invasive procedure subsequent to the formation of incision 12 in the patient's tissue “T”.
[0067] Prior to the insertion of apparatus 10 , elongated member 400 is in its first condition such that distal-most end 408 of elongated member 400 may be inserted into incision 12 . The user then advances apparatus 10 distally until flange 304 abuts tissue “T”. Thereafter, the user draws filaments 500 proximally, thereby transitioning elongated member 400 into its second condition and forming tissue engaging portion 416 . The user may then secure filaments 500 to locking structure 308 to thereby maintain the second condition of elongated member 400 and anchor apparatus 10 within incision 12 . Surgical object “I” may then be inserted into and advanced distally through lumen 402 of elongated member 400 to carry out the surgical procedure through apparatus 10 . It should be noted that the insertion of surgical object “I” may dilate elongated member 400 outwardly, thereby forcing tubular braid 404 outwardly along transverse axis “B” and into tighter engagement with tissue “T”, thereby further securing apparatus 10 and enhancing the quality of the seal formed by the engagement of tissue “T” with flange 304 and tissue engaging portion 416 .
[0068] After completing the procedure and withdrawing surgical object “I”, filaments 500 may be disengaged from locking structure 308 , e.g., untied, such that elongate member may return to its initial condition. Apparatus 10 may then be withdrawn from incision 12 and incision 12 may be closed.
[0069] Referring now to FIGS. 10A-10B , in another embodiment, apparatus 10 further includes a membrane 510 that is disposed about elongated member 400 . Membrane 510 may be composed of any suitable biocompatible material that is at least semi-resilient in nature and substantially impervious to fluids, e.g., blood or insufflation gas. The incorporation of membrane 510 may facilitate the insertion and passage of one or more surgical objects “I” into and through lumen 402 of elongated member 400 , and may constitute the means by which filaments 500 are secured to elongated member 400 . Membrane 510 may be disposed about elongated member 400 along its entire length, or in the alternative, membrane 510 may be selectively disposed about individual sections of elongated member 400 , e.g. proximal section 410 , intermediate section 412 , and/or distal section 414 .
[0070] When disposed about proximal section 410 of elongated member 400 , membrane 510 engages the patient's tissue “T” upon the transition of elongated member 400 from the first condition ( FIG. 10A ) into the second condition ( FIG. 10B ) thereof. The engagement of membrane 510 with tissue “T”, in conjunction with flange 304 of housing 300 , creates a substantially fluid-tight seal about incision 12 , thereby substantially preventing the escape of any fluids, e.g. blood or insufflation gas, if any, about apparatus 10 .
[0071] As previously discussed with respect to the embodiment of FIGS. 6-7 , the introduction of surgical object “I” to elongated member 400 forces tubular braid 404 outwardly along transverse axis “B”. In the embodiment of FIGS. 10A-10B , membrane 510 would also be forced outwardly and into tighter engagement with tissue “T”. Accordingly, membrane 510 may act to further anchor apparatus 10 within tissue “T” and tighten the seal created therewith by tissue engaging portion 416 and flange 304 .
[0072] Although the illustrative embodiments of the present disclosure have been described herein with reference to the accompanying drawings, the above description, disclosure, and figures should not be construed as limiting, but merely as exemplifications of particular embodiments. It is to be understood, therefore, that the disclosure is not limited to those precise embodiments, and that various other changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the disclosure. | The present disclosure relates to a surgical apparatus for positioning within an incision in tissue. In one aspect of the present disclosure, the surgical access apparatus includes an elongated seal member configured to removably receive at least one surgical object, and a deployment member. In another of the present disclosure, the surgical access apparatus includes a housing configured to removably receive at least one surgical object, an elongated member, and at least one filament. A method of percutaneously accessing an underlying surgical work site using the surgical apparatus is also disclosed. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 08/215,436, filed Mar. 21, 1994, now U.S. Pat. No. 5,538,659, which is a continuation-in-part of U.S. patent application Ser. No. 08/039,563, filed Mar. 29, 1993, abandoned.
FIELD OF THE INVENTION
This invention relates to compositions of mixture of hydrofluorocarbons. These compositions are useful as cleaning agents, expansion agents for polyolefins and polyurethanes, aerosol propellants, refrigerants, heat transfer media, gaseous dielectrics, fire extinguishing agents, power cycle working fluids, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents, and displacement drying agents.
BACKGROUND OF THE INVENTION
Fluorinated hydrocarbons have many uses, one of which is as a refrigerant. Such refrigerants include dichlorodifluoromethane (CFC-12) and chlorodifluoromethane (HCFC-22).
In recent years it has been pointed out that certain kinds of fluorinated hydrocarbon refrigerants released into the atmosphere may adversely affect the stratospheric ozone layer. Although this proposition has not yet been completely established, there is a movement toward the control of the use and the production of certain chlorofluorocarbons (CFCs) and hydrochlorofluorocarbons (HCFCs) under an international agreement.
Accordingly, there is a demand for the development of refrigerants that have a lower ozone depletion potential than existing refrigerants while still achieving an acceptable performance in refrigeration applications. Hydrofluorocarbons (HFCs) have been suggested as replacements for CFCs and HCFCs since HFCs have no chlorine and therefore have zero ozone depletion potential.
In refrigeration applications, a refrigerant is often lost during operation through leaks in shaft seals, hose connections, soldered joints and broken lines. In addition, the refrigerant may be released to the atmosphere during maintenance procedures on refrigeration equipment. If the refrigerant is not a pure component or an azeotropic or azeotrope-like composition, the refrigerant composition may change when leaked or discharged to the atmosphere from the refrigeration equipment, which may cause the refrigerant to become flammable or to have poor refrigeration performance.
Accordingly, it is desirable to use as a refrigerant a single fluorinated hydrocarbon or an azeotropic or azeotrope-like composition that includes one or more fluorinated hydrocarbons.
Fluorinated hydrocarbons may also be used as a cleaning agent or solvent to clean, for example, electronic circuit boards. It is desirable that the cleaning agents be azeotropic or azeotrope-like because in vapor degreasing operations the cleaning agent is generally redistilled and reused for final rinse cleaning.
Azeotropic or azeotrope-like compositions that include a fluorinated hydrocarbon are also useful as blowing agents in the manufacture of closed-cell polyurethane, phenolic and thermoplastic foams, as propellants in aerosols, as heat transfer media, gaseous dielectrics, fire extinguishing agents, power cycle working fluids such as for heat pumps, inert media for polymerization reactions, fluids for removing particulates from metal surfaces, as carrier fluids that may be used, for example, to place a fine film of lubricant on metal parts, as buffing abrasive agents to remove buffing abrasive compounds from polished surfaces such as metal, as displacement drying agents for removing water, such as from jewelry or metal parts, as resist developers in conventional circuit manufacturing techniques including chlorine-type developing agents, or as strippers for photoresists when used with, for example, a chlorohydrocarbon such as 1,1,1-trichloroethane or trichloroethylene.
SUMMARY OF THE INVENTION
The present invention relates to the discovery of refrigerant compositions of hexafluoropropane and a hydrofluorocarbon, with the hydrofluorocarbon being hexafluoropropane, pentafluoropropane, tetrafluoropropane, trifluoropropane, difluoropropane, fluoropropane, or HFC-356mmz. These compositions are also useful as cleaning agents, expansion agents for polyolefins and polyurethanes, aerosol propellants, heat transfer media, gaseous dielectrics, fire extinguishing agents, power cycle working fluids, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents, and displacement drying agents. Further, the invention relates to the discovery of binary azeotropic or azeotrope-like compositions comprising effective amounts of hexafluoropropane and hexafluoropropane, pentafluoropropane, tetrafluoropropane, trifluoropropane, difluoropropane, fluoropropane, or HFC-356mmz to form an azeotropic or azeotrope-like composition.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-236fa at 25° C.;
FIG. 2 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-245eb at 25° C.;
FIG. 3 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-245fa at 25° C.;
FIG. 4 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-254eb at 25° C.;
FIG. 5 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-263ca at 25° C.;
FIG. 6 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-263fb at 25° C.;
FIG. 7 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-272ca at 25° C.;
FIG. 8 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-272fb at 25° C.;
FIG. 9 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-281ea at 25° C.;
FIG. 10 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ca and HFC-356mmz at 25° C.;
FIG. 11 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-236ea at 25° C.;
FIG. 12 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-236fa at 25° C.;
FIG. 13 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-245fa at 25° C.;
FIG. 14 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-254cb at 25° C.;
FIG. 15 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-254eb at 25° C.;
FIG. 16 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-263fb at 25° C.;
FIG. 17 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-272ca at 25° C.;
FIG. 18 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-281ea at 25° C.;
FIG. 19 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236cb and HFC-281fa at 25° C.;
FIG. 20 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ea and HFC-236fa at 25° C.;
FIG. 21 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ea and HFC-245cb at 25° C.;
FIG. 22 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ea and HFC-263fb at 25° C.;
FIG. 23 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ea and HFC-272ca at 25° C.;
FIG. 24 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ea and HFC-272fb at 25° C.;
FIG. 25 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ea and HFC-281ea at 25° C.;
FIG. 26 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236ea and HFC-281fa at 25° C.;
FIG. 27 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-245ca at 25° C.;
FIG. 28 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-245eb at 25° C.;
FIG. 29 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-254ca at 25° C.;
FIG. 30 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-254cb at 25° C.;
FIG. 31 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-254eb at 25° C.;
FIG. 32 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-272ca at 25° C.;
FIG. 33 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-272ea at 25° C.;
FIG. 34 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-281ea at 25° C.; and
FIG. 35 is a graph of the vapor/liquid equilibrium curve for mixtures of HFC-236fa and HFC-281fa at 25° C.
DETAILED DESCRIPTION
The present invention relates to the following compositions:
(a) 1,1,2,2,3,3-hexafluoropropane (HFC-236ca) and 1,1,1,3,3,3-hexafluoropropane (HFC-236fa), 1,1,1,2,3-pentafluoropropane (HFC-245eb), 1,1,1,3,3-pentafluoropropane (HFC-245fa), 1,1,1,2-tetrafluoropropane (HFC-254eb), 1,2,2-trifluoropropane (HFC-263ca), 1,1,1-trifluoropropane (HFC-263fb), 2,2-difluoropropane (HFC-272ca), 1,1-difluoropropane (HFC-272fb), 2-fluoropropane (HFC-281ea) or (CF 3 ) 2 CHCH 3 (HFC-356mmz);
(b) 1,1,1,2,2,3-hexafluoropropane (HFC-236cb) and 1,1,2,3,3,3-hexafluoropropane (HFC-236ea), HFC-236fa, HFC-245fa, 1,1,2,2-tetrafluoropropane (HFC-254cb), HFC-254eb, HFC-263fb, HFC-272ca, HFC-272fb, HFC-281ea or 1-fluoropropane (HFC-281fa);
(c) HFC-236ea and HFC-236fa, 1,1,1,2,2-pentafluoropropane (HFC-245cb), HFC-263fb, HFC-272ca, HFC-272fb, HFC-281ea or HFC-281fa; or
(d) HFC-236fa and 1,1,2,2,3-pentafluoropropane (HFC-245ca), HFC-245eb, 1,2,2,3-tetrafluoropropane (HFC-254ca), HFC-254cb, HFC-254eb, HFC-272ca, HFC-272ea, HFC-281ea or HFC-281fa.
1-99 wt. % of each of the components of the compositions can be used as refrigerants. Further, the present invention also relates to the discovery of azeotropic or azeotrope-like compositions of effective amounts of each of the above mixtures to form an azeotropic or azeotrope-like composition.
By "azeotropic" composition is meant a constant boiling liquid admixture of two or more substances that behaves as a single substance. One way to characterize an azeotropic composition is that the vapor produced by partial evaporation or distillation of the liquid has the same composition as the liquid from which it was evaporated or distilled, that is, the admixture distills/refluxes without compositional change. Constant boiling compositions are characterized as azeotropic because they exhibit either a maximum or minimum boiling point, as compared with that of the non-azeotropic mixtures of the same components.
By "azeotrope-like" composition is meant a constant boiling, or substantially constant boiling, liquid admixture of two or more substances that behaves as a single substance. One way to characterize an azeotrope-like composition is that the vapor produced by partial evaporation or distillation of the liquid has substantially the same composition as the liquid from which it was evaporated or distilled, that is, the admixture distills/refluxes without substantial composition change.
It is recognized in the an that a composition is azeotrope-like if, after 50 weight percent of the composition is removed such as by evaporation or boiling off, the difference in vapor pressure between the original composition and the composition remaining after 50 weight percent of the original composition has been removed is less than 10 percent, when measured in absolute units. By absolute units, it is meant measurements of pressure and, for example, psia, atmospheres, bars, torr, dynes per square centimeter, millimeters of mercury, inches of water and other equivalent terms well known in the art. If an azeotrope is present, there is no difference in vapor pressure between the original composition and the composition remaining after 50 weight percent of the original composition has been removed.
Therefore, included in this invention are compositions of effective amounts of
(a) 1,1,2,2,3,3-hexafluoropropane (HFC-236ca) and 1,1,1,3,3,3-hexafluoropropane (HFC-236fa), 1,1,1,2,3-pentatluoropropane (HFC-245eb), 1,1,1,3,3-pentafluoropropane (HFC-245fa), 1,1,1,2-tetrafluoropropane (HFC-254eb), 1,2,2-trifluoropropane (HFC-263ca), 1,1,1-trifluoropropane (HFC-263fb), 2,2-difluoropropane (HFC-272ca), 1,1-difluoropropane (HFC-272fb), 2-fluoropropane (HFC-281ea) or (CF 3 ) 2 CHCH 3 (HFC-356mmz);
(b) 1,1,1,2,2,3-hexafluoropropane (HFC-236cb) and 1,1,2,3,3,3-hexafluoropropane (HFC-236ea), HFC-236fa, HFC-245fa, 1,1,2,2-tetrafluoropropane (HFC-254cb), HFC-254eb, HFC-263fb, HFC-272ca, HFC-272fb, HFC-281ea or HFC-281fa;
(c) HFC-236ea and HFC-236fa, HFC-245cb, HFC-263fb, HFC-272ca, HFC-272fb, HFC-281ea or HFC-281fa; or
(d) HFC-236fa and HFC-245ca, HFC-245eb, HFC-254ca, HFC-254cb, HFC-254eb, HFC-272ca, HFC-272ea, HFC-281ea or HFC-281fa;
such that after 50 weight percent of an original composition is evaporated or boiled off to produce a remaining composition, the difference in the vapor pressure between the original composition and the remaining composition is 10 percent or less.
For compositions that are azeotropic, there is usually some range of compositions around the azeotrope point that, for a maximum boiling azeotrope, have boiling points at a particular pressure higher than the pure components of the composition at that pressure and have vapor pressures at a particular temperature lower than the pure components of the composition at that temperature, and that, for a minimum boiling azeotrope, have boiling points at a particular pressure lower than the pure components of the composition at that pressure and have vapor pressures at a particular temperature higher than the pure components of the composition at that temperature. Boiling temperatures and vapor pressures above or below that of the pure components are caused by unexpected intermolecular forces between and among the molecules of the compositions, which can be a combination of repulsive and attractive forces such as van der Waals forces and hydrogen bonding.
The range of compositions that have a maximum or minimum boiling point at a particular pressure, or a maximum or minimum vapor pressure at a particular temperature, may or may not be coextensive with the range of compositions that have a change in vapor pressure of less than about 10% when 50 weight percent of the composition is evaporated. In those cases where the range of compositions that have maximum or minimum boiling temperatures at a particular pressure, or maximum or minimum vapor pressures at a particular temperature, are broader than the range of compositions that have a change in vapor pressure of less than about 10% when 50 weight percent of the composition is evaporated, the unexpected intermolecular forces are nonetheless believed important in that the refrigerant compositions having those forces that are not substantially constant boiling may exhibit unexpected increases in the capacity or efficiency versus the components of the refrigerant composition.
The components of the compositions of this invention have the following vapor pressures at 25° C.
______________________________________Components Psia kPa______________________________________HFC-236ca 24.9 172HFC-236cb 33.6 232HFC-236ea 29.8 206HFC-236fa 39.4 271HFC-245ca 14.2 98HFC-245cb 67.4 465HFC-245eb 16.9 117HFC-245fa 21.6 149HFC-254ca 13.7 95HFC-254cb 34.2 236HFC-254eb 34.8 240HFC-263ca 18.2 126HFC-263fb 54.0 372HFC-272ca 34.5 238HFC-272ea 20.8 143HFC-272fb 26.5 182HFC-281ea 47.1 325HFC-281fa 37.7 260HFC-356mmz 16.6 114______________________________________
Substantially constant boiling, azeotropic or azeotrope-like compositions of this invention comprise the following (all compositions are measured at 25° C.):
______________________________________ WEIGHT RANGES PREFERREDCOMPONENTS (wt. %/wt/%) (wt. %/wt. %)______________________________________HFC-236ca/HFC-236fa 1-99/1-99 1-80/20-99HFC-236ca/HFC-245eb 1-99/1-99 1-85/15-99HFC-236ca/HFC-245fa 1-99/1-99 20-99/1-80HFC-236ca/HFC-254eb 1-99/1-99 40-99/1-60HFC-236ca/HFC-263ca 1-99/1-99 20-99/1-80HFC-236ca/HFC-263fb 1-62/38-99 1-62/38-99HFC-236ca/HFC-272ca 1-81/19-99 20-81/19-80HFC-236ca/HFC-272fb 1-99/1-99 30-99/1-70HFC-236ca/HFC-281ea 1-78/22-99 1-78/22-99HFC-236ca/HFC-356mmz 1-99/1-99 50-99/1-50HFC-236cb/HFC-236ea 1-99/1-99 1-99/1-99HFC-236cb/HFC-236fa 1-99/1-99 1-99/1-99HFC-236cb/HFC-245fa 1-99/1-99 1-60/40-99HFC-236cb/HFC-254cb 1-99/1-99 20-99/1-80HFC-236cb/HFC-254eb 1-99/1-99 20-99/1-80HFC-236cb/HFC-263fb 1-99/1-99 1-99/1-99HFC-236cb/HFC-272ca 1-99/1-99 40-99/1-60HFC-236cb/HFC-272fb 1-99/1-99 20-99/1-80HFC-236cb/HFC-281ea 1-99/1-99 20-99/1-80HFC-236cb/HFC-281fa 1-99/1-99 20-99/1-80HFC-236ea/HFC-236fa 1-99/1-99 1-99/1-99HFC-236ea/HFC-245cb 1-45/55-99 1-45/55-99HFC-236ea/HFC-263fb 1-65/35-99 1-65/35-99HFC-236ea/HFC-272ca 1-99/1-99 20-99/1-80HFC-236ea/HFC-272fb 1-99/1-99 40-99/1-60HFC-236ea/HFC-281ea 1-87/13-99 15-87/13-85HFC-236ea/HFC-281fa 1-99/1-99 20-99/1-80HFC-236fa/HFC-245ca 72-99/1-28 72-99/1-28HFC-236fa/HFC-245eb 60-99/1-40 60-99/1-40HFC-236fa/HFC-254ca 68-99/1-32 68-99/1-32HFC-236fa/HFC-254cb 1-99.8/0.2-99 49-99.8/0.2-60HFC-236fa/HFC-254eb 1-99/1-99 40-99/1-60HFC-236fa/HFC-272ca 1-99/1-99 40-99/1-60HFC-236fa/HFC-272ea 64-99/1-36 64-99/1-36HFC-236fa/HFC-281ea 1-99/1-99 40-99/1-60HFC-236fa/HFC-281fa 1-99/1-99 40-99/1-60______________________________________
For purposes of this invention, "effective amount" is defined as the amount of each component of the inventive compositions which, when combined, results in the formation of an azeotropic or azeotrope-like composition. This definition includes the amounts of each component, which amounts may vary depending on the pressure applied to the composition so long as the azeotropic or azeotrope-like compositions continue to exist at the different pressures, but with possible different boiling points.
Therefore, effective amount includes the amounts, such as may be expressed in weight percentages, of each component of the compositions of the instant invention which form azeotropic or azeotrope-like compositions at temperatures or pressures other than as described herein.
For the purposes of this discussion, azeotropic or constant-boiling is intended to mean also essentially azeotropic or essentially-constant boiling. In other words, included within the meaning of these terms are not only the true azeotropes described above, but also other compositions containing the same components in different proportions, which are true azeotropes at other temperatures and pressures, as well as those equivalent compositions which are part of the same azeotropic system and are azeotrope-like in their properties. As is well recognized in this art, there is a range of compositions which contain the same components as the azeotrope, which will not only exhibit essentially equivalent properties for refrigeration and other applications, but which will also exhibit essentially equivalent properties to the true azeotropic composition in terms of constant boiling characteristics or tendency not to segregate or fractionate on boiling.
It is possible to characterize, in effect, a constant boiling admixture which may appear under many guises, depending upon the conditions chosen, by any of several criteria:
The composition can be defined as an azeotrope of A, B, C (and D . . . ) since the very term "azeotrope" is at once both definitive and limitative, and requires that effective amounts of A, B, C (and D . . . ) for this unique composition of matter which is a constant boiling composition.
It is well known by those skilled in the art, that, at different pressures, the composition of a given azeotrope will vary at least to some degree, and changes in pressure will also change, at least to some degree, the boiling point temperature. Thus, an azeotrope of A, B, C (and D . . . ) represents a unique type of relationship but with a variable composition which depends on temperature and/or pressure. Therefore, compositional ranges, rather than fixed compositions, are often used to define azeotropes.
The composition can be defined as a particular weight percent relationship or mole percent relationship of A, B, C (and D . . . ), while recognizing that such specific values point out only one particular relationship and that in actuality, a series of such relationships, represented by A, B, C (and D . . . ) actually exist for a given azeotrope, varied by the influence of pressure.
An azeotrope of A, B, C (and D . . . ) can be characterized by defining the compositions as an azeotrope characterized by a boiling point at a given pressure, thus giving identifying characteristics without unduly limiting the scope of the invention by a specific numerical composition, which is limited by and is only as accurate as the analytical equipment available.
The azeotrope or azeotrope-like compositions of the present invention can be prepared by any convenient method including mixing or combining the desired amounts. A preferred method is to weigh the desired component amounts and thereafter combine them in an appropriate container.
Specific examples illustrating the invention are given below. Unless otherwise stated therein, all percentages are by weight. It is to be understood that these examples are merely illustrative and in no way are to be interpreted as limiting the scope of the invention.
EXAMPLE 1
Phase Study
A phase study shows the following compositions are azeotropic, all at 25° C.
______________________________________ Vapor Press.Composition No. psia (kPa)______________________________________HFC-236ca/HFC-236fa 7.6/92.4 39.5 272HFC-236ca/HFC-245eb 9.1/90.9 16.9 117HFC-236ca/HFC-245fa 98.3/1.7 24.9 172HFC-236ca/HFC-254eb 77.4/22.6 21.7 150HFC-236ca/HFC-263ca 35.4/64.6 17.8 123HFC-236ca/HFC-263fb 13.7/86.3 54.6 376HFC-236ca/HFC-272ca 46.8/53.2 40.2 277HFC-236ca/HFC-272fb 56.1/43.9 29.0 200HFC-236ca/HFC-281ea 16.3/83.7 47.4 327HFC-236ca/HFC-356mmz 78.1/21.9 25.8 178HFC-236cb/HFC-236ea 36.7/63.3 27.6 190HFC-236cb/HFC-236fa 28.2/71.8 41.7 288HFC-236cb/HFC-245fa 25.6/74.4 20.5 141HFC-236cb/HFC-254cb 52.1/47.9 28.8 199HFC-236cb/HFC-254eb 39.0/61.0 35.2 243HFC-236cb/HFC-263fb 19.0/81.0 55.0 379HFC-236cb/HFC-272ca 58.2/41.8 41.3 285HFC-236cb/HFC-272fb 45.0/55.0 26.1 180HFC-236cb/HFC-281ea 39.1/60.9 48.9 337HFC-236cb/HFC-281fa 56.1/43.9 40.4 279HFC-236ea/HFC-236fa 17.6/82.4 41.4 285HFC-236ea/HFC-245cb 3.7/96.3 67.6 466HFC-236ea/HFC-263fb 20.0/80.0 56.2 387HFC-236ea/HFC-272ca 50.0/50.0 41.7 288HFC-236ea/HFC-272fb 75.0/25.0 31.0 214HFC-236ea/HFC-281ea 33.9/66.1 48.7 336HFC-236ea/HFC-281fa 44.8/55.2 39.9 275HFC-236fa/HFC-245ca 98.0/2.0 39.5 272HFC-236fa/HFC-245eb 90.4/9.6 40.6 280HFC-236fa/HFC-254ca 92.4/7.6 40.8 281HFC-236fa/HFC-254cb 99.8/0.2 39.4 272HFC-236fa/HFC-254eb 74.4/25.6 41.5 286HFC-236fa/HFC-272ca 79.3/20.7 40.6 280HFC-236fa/HFC-272ea 88.9/11.1 43.2 298HFC-236fa/HFC-281ea 62.5/37.5 54.0 372HFC-236fa/HFC-281fa 75.3/24.7 48.4 334______________________________________
EXAMPLE 2
Impact of Vapor Leakage on Vapor Pressure at 25° C.
A vessel is charged with an initial composition at 25° C., and the initial vapor pressure of the composition is measured. The composition is allowed to leak from the vessel, while the temperature is held constant at 25° C., until 50 weight percent of the initial composition is removed, at which time the vapor pressure of the composition remaining in the vessel is measured. The results are summarized below.
______________________________________ INITIAL 50% LEAK DELTAWT % A/WT % B PSIA KPA PSIA KPA % P______________________________________HFC-236ca/HFC-236fa7.6/92.4 39.5 272 39.5 272 0.01/99 39.4 272 39.4 272 0.040/60 37.8 261 37.2 256 1.660/40 35.4 244 33.6 232 5.180/20 31.5 217 28.8 199 8.685/15 30.2 208 27.6 190 8.699/1 25.4 175 25.1 173 1.2HFC-236ca/HFC-245eb9.1/90.9 16.9 117 16.9 117 0.01/99 16.9 117 16.9 117 0.040/60 17.4 120 17.3 119 0.660/40 20. 138 19.1 132 4.585/15 22.5 155 21.4 148 4.999/1 24.8 171 24.8 171 0.0HFC-236ca/HFC-245fa98.3/1.7 24.9 172 24.9 172 0.099/1 24.9 172 24.9 172 0.060/40 24.4 168 24.3 168 0.440/60 23.7 163 23.6 163 0.420/80 22.8 157 22.7 157 0.41/99 21.7 150 21.7 150 0.0HFC-236ca/HFC-254eb77.4/22.6 21.7 150 21.7 150 0.090/10 23. 159 22.5 155 2.299/1 24.8 171 24.8 171 0.050/50 25.2 174 23.5 162 6.745/55 26.1 180 24.2 167 7.340/60 27.1 187 25.1 173 7.430/70 29.2 201 27.1 187 7.220/80 31.1 214 29.5 203 5.11/99 34.6 239 34.5 238 0.3HFC-236ca/HFC-263ca35.4/64.6 17.8 123 17.8 123 0.020/80 17.9 123 17.9 123 0.01/99 18.2 125 18.2 125 0.060/40 18.4 127 18.2 125 1.180/20 20.6 142 19.7 136 4.490/10 22.7 157 21.7 150 4.499/1 24.8 171 24.7 170 0.4HFC-236ca/HFC-263fb13.7/86.3 54.6 376 54.6 376 0.01/99 54.1 373 54.1 373 0.040/60 53.1 366 52. 359 2.160/40 49.8 343 45.4 313 8.865/35 48.5 334 42.7 294 12.37 49. 338 43.8 302 10.638 49.3 340 44.4 306 9.9HFC-236ca/HFC-272ca46.8/53.2 40.2 277 40.2 277 0.020/80 38.8 268 37.5 259 3.41/99 34.9 241 34.6 239 0.910/90 37.2 256 35.8 247 3.870/30 39. 269 37.6 259 3.685/15 35.7 246 31.2 215 12.682/18 36.7 253 32.8 226 10.681/19 36.9 254 33.3 230 9.8HFC-236ca/HFC-272fb56.1/43.9 29. 200 29. 200 0.030/70 28.4 196 28.2 194 0.710/90 27.2 188 27. 186 0.71/99 26.5 183 26.5 183 0.080/20 28.2 194 27.9 192 1.199/1 25.2 174 25.1 173 0.4HFC-236ca/HFC-281ea16.3/83.7 47.4 327 47.4 327 0.01/99 47.2 325 47.2 325 0.040/60 46.8 323 46.5 321 0.660/40 45. 310 43.7 301 2.980/20 40.6 280 36.1 249 11.178/22 41.3 285 37.2 256 9.9HFC-236ca/HFC-356mmz78.1/21.9 25.8 178 25.8 178 0.090/10 25.6 177 25.5 176 0.499/1 25. 172 25. 172 0.050/50 24.9 172 24.3 168 2.430/70 23. 159 21.4 148 7.20/80 21.6 149 19.5 134 9.718/82 21.2 146 19.2 132 9.410/90 19.5 134 17.8 123 8.71/99 16.9 117 16.7 115 1.2HFC-236cb/HFC-236ea36.7/63.3 27.6 190 27.6 190 0.020/80 28.3 195 28.1 194 0.71/99 29.9 206 29.9 206 0.060/40 28.7 198 28.4 196 4.580/20 30.9 213 30.4 210 1.699/1 33.5 231 33.4 230 0.3HFC-236cb/HFC-236fa28.2/71.8 41.7 288 41.7 288 0.085 41.3 285 41.2 284 0.21/99 39.6 273 39.5 272 0.360/40 40. 276 39.5 272 1.380/20 37.5 259 36.6 252 2.499/1 33.8 233 33.8 233 0.0HFC-236cb/HFC-245fa25.6/74.4 20.5 141 20.5 141 0.010/90 21.3 147 21.1 145 0.91/99 21.7 150 21.7 150 0.060/40 24.4 168 22.7 157 7.65/35 25.4 175 23.5 162 7.570/30 26.5 183 24.4 168 7.980/20 28.8 199 26.9 185 6.699/1 33.4 230 33.2 229 0.6HFC-236cb/HFC-254cb52.1/47.9 28.8 199 28.8 199 0.080/20 30.7 212 30.3 209 1.399/1 33.4 230 33.4 230 0.020/80 31.7 219 30.9 213 2.51/99 34.2 236 34.2 236 0.0HFC-236cb/HFC-254eb39/61 35.2 243 35.2 243 0.020/80 35.1 242 35.1 242 0.01/99 34.8 240 34.8 240 0.070/30 34.8 240 34.8 240 0.090/10 34.2 236 34.1 235 0.399/1 33.7 232 33.7 232 0.0HFC-236cb/HFC-263fb19/81 55. 379 55. 379 0.010/90 54.8 378 54.8 378 0.01/99 54.1 373 54.1 373 0.050/50 53. 365 51.7 356 2.580/20 45.4 313 41.3 285 9.82/18 44.6 308 40.4 279 9.484/16 43.7 301 39.5 272 9.685/15 43.2 298 39.1 270 9.599/1 34.4 237 33.9 234 1.5HFC-236cb/HFC-272ca58.2/41.8 41.3 285 41.3 285 0.080/20 40. 276 39.3 271 1.899/1 34.2 236 33.9 234 0.920/80 38.8 268 37.4 258 3.61/99 34.8 240 34.6 239 0.6HFC-236cb/HFC-272fb45/55 26.1 180 26.1 180 0.020/80 26.7 184 26.7 184 0.01/99 26.7 184 26.5 183 0.775/25 28.1 194 27.5 190 2.199/1 33.3 230 33.2 229 0.3HFC-236cb/HFC-281ea39.1/60.9 48.9 337 48.9 337 0.020/80 48.5 334 48.4 334 0.21/99 47.2 325 47.2 325 0.070/30 47.1 325 46.1 318 2.185/15 43.5 300 41.1 283 5.592/8 40.1 276 37.6 259 6.299/1 34.7 239 34.1 235 1.7HFC-236cb/HFC-281fa56.1/43.9 40.4 279 40.4 279 0.080/20 39.2 270 38.8 268 1.99/1 34.1 235 34. 234 0.320/80 39.1 270 38.9 268 0.51/99 37.8 261 37.8 261 0.0HFC-236ea/HFC-236fa17.6/82.4 41.4 285 41.4 285 0.01/99 39.7 274 39.6 273 0.340/60 40.2 277 39.6 273 1.560/40 37.6 259 36.3 250 3.580/20 34.1 235 32.8 226 3.899/1 30.1 208 30.0 207 0.3HFC-236ea/HFC-245cb3.7/96.3 67.6 466 67.6 466 0.01/99 67.5 465 67.5 465 0.020/80 65.9 454 64.8 447 1.740/60 61.1 421 56.3 388 7.945/55 59.5 410 53.6 370 9.946/54 59.2 408 53.0 365 10.5HFC-236ea/HFC-263fb20.0/80.0 56.2 387 56.2 387 0.01/99 54.3 374 54.2 374 0.250/50 53.7 370 51.5 355 4.165/35 50.2 346 45.4 313 9.666/34 49.9 344 44.9 310 10.0HFC-236ea/HFC-272ca50.0/50.0 41.7 288 41.7 288 0.025/75 40.6 280 39.2 270 3.41/99 35.0 241 34.6 239 1.175/25 40.0 276 38.7 267 3.299/1 30.6 211 30.1 208 1.6HFC-236ea/HFC-272fb75.0/25.0 31.0 214 31.0 214 0.099/1 30.0 207 29.9 206 0.340/60 29.9 206 29.6 204 1.020/80 28.5 197 28.0 193 1.81/99 26.6 183 26.5 183 0.4HFC-236ea/HFC-281ea33.9/66.1 48.7 336 48.7 336 0.015/85 48.2 332 48.1 332 0.21/99 47.2 325 47.2 325 0.060/40 47.5 328 46.8 323 1.580/20 43.7 301 40.5 279 7.387/13 40.8 281 36.8 254 9.888/12 40.3 278 36.2 250 10.2HFC-236ea/HFC-281fa44.8/55.2 39.9 275 39.9 275 0.020/80 39.2 270 39.0 269 0.51/99 37.8 261 37.8 261 0.060/40 39.6 273 39.4 272 0.580/20 37.4 258 36.4 251 2.799/1 30.5 210 30.2 208 1.0HFC-236fa/HFC-245ca98/2 39.5 272 39.5 272 0.099/1 39.4 272 39.4 272 0.060/40 32.9 227 27.4 189 16.770/30 35.4 244 31.5 217 11.72/28 35.8 247 32.4 223 9.5HFC-236fa/HFC-245eb90.4/9.6 40.6 280 40.6 280 0.099/1 39.7 274 39.6 273 0.360/40 37.6 259 34.1 235 9.359/41 37.5 259 33.7 232 10.1HFC-236fa/HFC-254ca92.4/7.6 40.8 281 40.8 281 0.099/1 39.9 275 39.6 273 0.860/40 36.9 254 30.7 212 16.870/30 38.7 267 35.6 245 8.67/33 38.3 264 34.3 236 10.468/32 38.4 265 34.8 240 9.4HFC-236fa/HFC-254cb99.8/0.2 39.4 272 39.4 272 0.070/30 38.8 268 38.7 267 0.340/60 37.3 257 37.1 256 0.520/80 35.9 248 35.7 246 0.61/99 34.3 236 34.2 236 0.3HFC-236fa/HFC-254eb74.4/25.6 41.5 286 41.5 286 0.090/10 40.9 282 40.7 281 0.599/1 39.6 273 39.5 272 0.340/60 39.7 274 39.3 271 1.20/80 37.6 259 37. 255 1.61/99 34.9 241 34.9 241 0.0HFC-236fa/HFC-272ca79.3/20.7 40.6 280 40.6 280 0.090/10 40.3 278 40.3 278 0.099/1 39.5 272 39.5 272 0.040/60 38.7 267 38.2 263 1.320/80 36.9 254 36.3 250 1.61/99 34.6 239 34.6 239 0.0HFC-236fa/HFC-272ea88.9/11.1 43.2 298 43.2 298 0.099/1 40.6 280 39.8 274 2.60/40 39.6 273 34.6 239 12.665/35 40.6 280 36.9 254 9.164/36 40.4 279 36.4 251 9.9HFC-236fa/HFC-281ea62.5/37.5 54. 372 54. 372 0.080/20 52.8 364 51.7 356 2.190/10 49.7 343 46.5 321 6.495/5 46.2 319 42.6 294 7.899/1 41.2 284 39.9 275 3.240/60 52.8 364 52.2 360 1.120/80 50.4 347 49.4 341 2.10/90 48.9 337 48.2 332 1.41/99 47.3 326 47.2 325 0.2HFC-236fa/HFC-281fa75.3/24.7 48.4 334 48.4 334 0.090/10 46.9 323 45.6 314 2.899/1 40.9 282 39.9 275 2.440/60 45.2 312 43.3 299 4.220/80 41.8 288 39.9 275 4.510/90 39.8 274 38.6 266 3.1/99 37.9 261 37.8 261 0.3______________________________________
The results of this Example show that these compositions are azeotropic or azeotrope-like because when 50 wt. % of an original composition is removed, the vapor pressure of the remaining composition is within about 10% of the vapor pressure of the original composition, at a temperature of 25° C.
EXAMPLE 3
Impact of Vapor Leakage at -25° C.
A leak test is performed on compositions of HFC-236fa and HFC-272ea, at the temperature of -25° C. The results are summarized below.
______________________________________ INITIAL 50% LEAK DELTAWT % A/WT % B PSIA KPA PSIA KPA % P______________________________________HFC-236fa/HFC-272ea87.9/12.1 5.68 39.2 5.68 39.2 0.099/1 5.27 36.3 5.05 34.8 4.264/36 5.34 36.8 4.84 33.4 9.463/37 5.32 36.7 4.78 33.0 10.2______________________________________
These results show that compositions of HFC-236fa and HFC-272ea are azeotropic or azeotrope-like at different temperatures, but that the weight percents of the components vary as the temperature is changed.
EXAMPLE 4
Refrigerant Performance
The following table shows the performance of various refrigerants. The data are based on the following conditions.
______________________________________Evaporator temperature 48.0° F. (8.9° C.)Condenser temperature 115.0° F. (46.1° C.)Subcooled 12.0° F. (6.7° C.)Return gas 65.0° F. (18.3° C.)Compressor efficiency is 75%.______________________________________
The refrigeration capacity is based on a compressor with a fixed displacement of 3.5 cubic feet per minute and 75% volumetric efficiency. Capacity is intended to mean the change in enthalpy of the refrigerant in the evaporator per pound of refrigerant circulated, i.e. the heat removed by the refrigerant in the evaporator per time. Coefficient of performance (COP) is intended to mean the ratio of the capacity to compressor work. It is a measure of refrigerant energy efficiency.
__________________________________________________________________________ Evap. Cond. CapacityRefrig. Press. Press. Comp. Dis. BTU/minComp. Psia (kPa) Psia (kPa) Temp. °F. (°C.) COP (kw)__________________________________________________________________________CFC-11 8 (55) 30 (207) 167 (75) 5.10 50 (0.9)HCFC-22 95 (655) 258 (1779) 183 (84) 4.60 397 (7.0)HFC-236ca/HFC-236fa1.0/99.0 21 (145) 69 (476) 129 (54) 4.71 103 (1.8)7.6/92.4 21 (145) 69 (476) 129 (54) 4.71 102 (1.8)95.0/5.0 14 (97) 50 (345) 134 (57) 4.85 77 (1.4)HFC-236ca/HFC-245eb1.0/99.0 9 (62) 34 (234) 139 (59) 4.95 53 (0.9)9.1/90.9 9 (62) 35 (241) 138 (59) 4.95 54 (1.0)95.0/5.0 14 (97) 48 (331) 134 (57) 4.85 73 (1.3)HFC-236ca/HFC-245fa5.0/95.0 12 (83) 43 (296) 137 (58) 4.9 66 (1.2)98.3/1.7 14 (97) 48 (331) 134 (57) 4.85 74 (1.3)99.0/1.0 14 (97) 49 (338) 134 (57) 4.85 74 (1.3)HFC-236ca/HFC-254eb5.0/95.0 20 (138) 64 (441) 137 (58) 4.85 100 (1.8)77.4/22.6 15 (103) 53 (365) 135 (57) 4.86 81 (1.4)95.0/5.0 14 (97) 50 (345) 134 (57) 4.84 76 (1.3)HFC-236ca/HFC-263ca5.0/95.0 10 (69) 36 (248) 143 (62) 4.99 57 (1.0)35.4/64.6 11 (76) 39 (269) 141 (61) 4.96 62 (1.1)95.0/5.0 14 (97) 48 (331) 135 (57) 4.85 73 (1.3)HFC-236ca/HFC-263fb5.0/95.0 31 (214) 95 (655) 137 (58) 4.76 145 (2.6)13.7/86.3 30 (207) 91 (627) 137 (58) 4.77 139 (2.4)95.0/5.0 15 (103) 51 (352) 134 (57) 4.87 79 (1.4)HFC-236ca/HFC-272ca5.0/95.0 20 (138) 63 (434) 142 (61) 4.92 100 (1.8)46.8/53.2 18 (124) 59 (407) 139 (59) 4.96 94 (1.7)95.0/5.0 14 (97) 50 (345) 135 (57) 4.85 77 (1.4)HFC-236ca/HFC-272fb5.0/95.0 15 (103) 51 (352) 148 (64) 4.99 81 (1.4)56.1/43.9 15 (103) 52 (359) 141 (61) 4.92 82 (1.4)95.0/5.0 14 (97) 50 (345) 135 (57) 4.86 76 (1.3)HFC-236ca/HFC-281ea5.0/95.0 28 (193) 84 (579) 147 (64) 4.92 135 (2.4)16.3/83.7 27 (186) 82 (565) 146 (63) 4.91 132 (2.3)95.0/5.0 15 (103) 53 (365) 135 (57) 4.88 81 (1.4)HFC-236ca/HFC-356mmz5.0/95.0 9 (62) 34 (234) 123 (51) 4.78 50 (0.9)78.1/21.9 13 (90) 45 (310) 131 (55) 4.83 69 (1.2)95.0/5.0 14 (97) 48 (331) 133 (56) 4.84 73 (1.3)HFC-236cb/HFC-236ea5.0/95.0 16 (110) 56 (386) 133 (56) 4.81 85 (1.5)36.7/63.3 17 (117) 58 (400) 132 (56) 4.79 88 (1.5)95.0/5.0 19 (131) 63 (434) 130 (54) 4.74 95 (1.7)HFC-236cb/HFC-236fa5.0/95.0 21 (145) 69 (476) 129 (54) 4.71 103 (1.8)28.2/71.8 21 (145) 67 (462) 129 (54) 4.71 100 (1.8)95.0/5.0 19 (131) 64 (441) 129 (54) 4.74 95 (1.7)HFC-236cb/HFC-245fa5.0/95.0 12 (83) 43 (296) 137 (58) 4.9 67 (1.2)25.6/74.4 14 (97) 47 (324) 135 (57) 4.89 73 (1.3)95.0/5.0 19 (131) 62 (427) 130 (54) 4.74 94 (1.7)HFC-236cb/HFC-254cb5.0/95.0 20 (138) 64 (441) 136 (58) 4.85 99 (1.7)52.1/47.9 20 (138) 64 (441) 133 (56) 4.8 98 (1.7)95.0/5.0 19 (131) 64 (441) 130 (54) 4.75 96 (1.7)HFC-236cb/HFC-254eb5.0/95.0 20 (138) 65 (448) 136 (58) 4.85 101 (1.8)39.0/61.0 20 (138) 65 (448) 134 (57) 4.81 100 (1.8)95.0/5.0 20 (138) 64 (441) 130 (54) 4.75 96 (1.7)HFC-236cb/HFC-263fb5.0/95.0 32 (221) 96 (662) 137 (58) 4.76 146 (2.6)19.0/81.0 30 (207) 93 (641) 136 (58) 4.76 141 (2.5)95.0/5.0 20 (138) 66 (455) 130 (54) 4.75 99 (1.7)HFC-236cb/HFC-272ca5.0/95.0 20 (138) 63 (434) 141 (61) 4.93 101 (1.8)58.2/41.8 21 (145) 66 (455) 135 (57) 4.84 102 (1.8)95.0/5.0 20 (138) 64 (441) 130 (54) 4.75 97 (1.7)HFC-236cb/HFC-272fb5.0/95.0 15 (103) 51 (352) 147 (64) 5 83 (1.5)45.0/55.0 18 (124) 59 (407) 141 (61) 4.91 92 (1.6)95.0/5.0 20 (138) 64 (441) 130 (54) 4.76 96 (1.7)HFC-236cb/HFC-281ea5.0/95.0 28 (193) 85 (586) 147 (64) 4.92 136 (2.4)39.1/60.9 28 (193) 84 (579) 142 (61) 4.87 133 (2.3)95.0/5.0 21 (145) 67 (462) 131 (55) 4.76 102 (1.8)HFC-236cb/HFC-281fa5.0/95.0 22 (152) 70 (483) 148 (64) 4.94 112 (2.0)56.1/43.9 23 (159) 73 (503) 140 (60) 4.86 114 (2.0)95.0/5.0 20 (138) 66 (455) 131 (55) 4.76 100 (1.8)HFC-236ea/HFC-236fa5.0/95.0 21 (145) 69 (476) 129 (54) 4.71 102 (1.8)17.6/82.4 21 (145) 67 (462) 130 (54) 4.74 100 (1.8)95.0/5.0 16 (110) 56 (386) 133 (56) 4.8 85 (1.5)HFC-236ea/HFC-245cb1.0/99.0 38 (262) 111 (765) 124 (51) 4.55 159 (2.8)3.7/96.3 37 (255) 109 (752) 124 (51) 4.56 157 (2.8)95.0/5.0 17 (117) 58 (400) 133 (56) 4.82 88 (1.5)HFC-236ea/HFC-263fb5.0/95.0 32 (221) 96 (662) 137 (58) 4.76 146 (2.6)20.0/80.0 29 (200) 91 (627) 137 (58) 4.78 138 (2.4)95.0/5.0 17 (117) 58 (400) 134 (57) 4.82 89 (1.6)HFC-236ea/HFC-272ca5.0/95.0 20 (138) 63 (434) 141 (61) 4.93 101 (1.8)50.0/50.0 19 (131) 61 (421) 138 (59) 4.89 97 (1.7)95.0/5.0 17 (117) 57 (393) 134 (57) 4.82 86 (1.5)HFC-236ea/HFC-272fb5.0/95.0 15 (103) 51 (352) 148 (64) 4.98 82 (1.4)75.0/25.0 17 (117) 56 (386) 138 (59) 4.87 88 (1.5)95.0/5.0 16 (110) 56 (386) 134 (57) 4.82 86 (1.5)HFC-236ea/HFC-281ea5.0/95.0 28 (193) 85 (586) 147 (64) 4.91 135 (2.4)33.9/66.1 26 (179) 81 (558) 145 (63) 4.89 128 (2.3)95.0/5.0 18 (124) 59 (407) 135 (57) 4.84 91 (1.6)HFC-236ea/HFC-281fa5.0/95.0 22 (152) 70 (483) 148 (64) 4.95 112 (2.0)44.8/55.2 21 (145) 69 (476) 144 (62) 4.91 109 (i.9)95.0/5.0 17 (117) 58 (400) 135 (57) 4.83 89 (1.6)HFC-236fa/HFC-245ca5.0/95.0 8 (55) 30 (207) 139 (59) 5.0 47 (0.8)98.0/2.0 21 (145) 68 (469) 129 (54) 4.71 101 (1.8)99.0/1.0 21 (145) 69 (476) 129 (54) 4.71 102 (1.8)HFC-236fa/HFC-245eb5.0/95.0 10 (69) 35 (241) 138 (59) 4.96 55 (1.0)90.4/9.6 20 (138) 65 (448) 130 (54) 4.75 97 (1.7)99.0/1.0 21 (145) 69 (476) 129 (54) 4.71 103 (1.8)HFC-236fa/HFC-254ca5.0/95.0 8 (55) 29 (200) 142 (61) 5.05 46 (0.8)92.4/7.6 19 (131) 64 (441) 130 (54) 4.75 96 (1.7)99.0/1.0 21 (145) 69 (476) 129 (54) 4.71 102 (1.8)HFC-236fa/HFC-254cb5.0/95.0 20 (138) 64 (441) 136 (58) 4.85 100 (1.8)99.8/0.2 21 (145) 69 (476) 129 (54) 4.71 103 (1.8)HFC-236fa/HFC-254eb5.0/95.0 20 (138) 65 (448) 136 (58) 4.84 101 (1.8)74.4/25.6 21 (145) 69 (476) 131 (55) 4.75 104 (1.8)95.0/5.0 21 (145) 69 (476) 129 (54) 4.72 103 (1.8)HFC-236fa/HFC-272ca5.0/95.0 20 (138) 64 (441) 141 (61) 4.92 102 (1.8)79.3/20.7 22 (152) 70 (483) 132 (56) 4.78 106 (1.9)95.0/5.0 22 (152) 70 (483) 130 (54) 4.73 104 (1.8)HFC-236fa/HFC-272ea5.0/95.0 12 (83) 41 (283) 149 (65) 5.05 67 (1.2)88.9/11.1 21 (145) 67 (462) 132 (56) 4.76 101 (1.8)95.0/5.0 21 (145) 68 (469) 130 (54) 4.73 102 (1.8)HFC-236fa/HFC-281ea5.0/95.0 28 (193) 85 (586) 147 (64) 4.92 136 (2.4)62.5/37.5 27 (186) 84 (579) 138 (59) 4.82 130 (2.3)95.0/5.0 23 (159) 73 (503) 131 (55) 4.73 109 (1.9)HFC-236fa/HFC-281fa5.0/9.5.0 22 (152) 70 (483) 148 (64) 4.95 113 (2.0)75.3/24.7 24 (165) 76 (524) 136 (58) 4.79 116 (2.0)95.0/5.0 22 (152) 72 (496) 130 (54) 4.73 107 (1.9)__________________________________________________________________________
EXAMPLE 5
This Example is directed to measurements of the liquid/vapor equilibrium curves for the mixtures in FIGS. 1-35.
Turning to FIG. 1, the upper curve represents the composition of the liquid, and the lower curve represents the composition of the vapor.
The data for the compositions of the liquid in FIG. 1 are obtained as follows. A stainless steel cylinder is evacuated, and a weighed amount of HFC-236ca is added to the cylinder. The cylinder is cooled to reduce the vapor pressure of HFC-236ca, and then a weighed amount of HFC-236fa is added to the cylinder. The cylinder is agitated to mix the HFC-236ca and HFC-236fa, and then the cylinder is placed in a constant temperature bath until the temperature comes to equilibrium at 25° C., at which time the vapor pressure of the HFC-236ca and HFC-236fa in the cylinder is measured. Additional samples of liquid are measured the same way, and the results are plotted in FIG. 1.
The curve which shows the composition of the vapor is calculated using an ideal gas equation of state.
Vapor/liquid equilibrium data are obtained in the same way for the mixtures shown in FIGS. 2-35.
The data in FIGS. 1, 3, 6-10, 12 and 15-35 show that at 25° C., there are ranges of compositions that have vapor pressures higher than the vapor pressures of the pure components of the composition at that same temperature. As stated earlier, the higher than expected pressures of these compositions may result in an unexpected increase in the refrigeration capacity or efficiency of those compositions when compared to the pure components of the compositions.
The data in FIGS. 2, 4-5, 11 and 13-14 show that at 25° C., there are ranges of compositions that have vapor pressures below the vapor pressures of the pure components of the composition at that same temperature. These minimum boiling compositions are useful in refrigeration, and may show an improved efficiency when compared to the pure components of the composition.
The novel compositions of this invention, including the azeotropic or azeotrope-like compositions, may be used to produce refrigeration by condensing the compositions and thereafter evaporating the condensate in the vicinity of a body to be cooled. The novel compositions may also be used to produce heat by condensing the refrigerant in the vicinity of the body to be heated and thereafter evaporating the refrigerant.
In addition to refrigeration applications, the novel constant boiling or substantially constant boiling compositions of the invention are also useful as aerosol propellants, heat transfer media, gaseous dielectrics, fire extinguishing agents, expansion agents for polyolefins and polyurethanes and power cycle working fluids.
ADDITIONAL COMPOUNDS
Other components, such as aliphatic hydrocarbons having a boiling point of -60° to +60° C., hydrofluorocarbonalkanes having a boiling point of -60° to +60° C., hydrofluoropropanes having a boiling point of between -60° to +60° C., hydrocarbon esters having a boiling point between -60° to +60° C., hydrochlorofluorocarbons having a boiling point between -60° to +60° C., hydrofluorocarbons having a boiling point of -60° to +60° C., hydrochlorocarbons having a boiling point between -60° to +60° C., chlorocarbons and perfluorinated compounds, can be added to the azeotropic or azeotrope-like compositions described above without substantially changing the properties thereof, including the constant boiling behavior, of the compositions.
Additives such as lubricants, corrosion inhibitors, suffactants, stabilizers, dyes and other appropriate materials may be added to the novel compositions of the invention for a variety of purposes provides they do not have an adverse influence on the composition for its intended application. Preferred lubricants include esters having a molecular weight greater than 250. | This invention relates to compositions of a hexafluoropropane and a hydrofluorocarbon, with the hydrofluorocarbon being hexafluoropropane, pentafluoropropane, tetrafluoropropane, trifluoropropane, difluoropropane, fluoropropane, or (CF 3 ) 2 CHCH 3 . The compositions, which may be azeotropic or azeotrope-like, may be used as refrigerants, cleaning agents, expansion agents for polyolefins and polyurethanes, aerosol propellants, refrigerants, heat transfer media, gaseous dielectrics, fire extinguishing agents, power cycle working fluids, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents or displacement drying agents. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to the care and cleaning of garments, and more particularly to the restoration of garments that are wrinkled, stretched out of shape, odorous, or slightly soiled, without the use of laundry compositions and using very little water.
BACKGROUND OF THE INVENTION
[0002] Articles of clothing preferably look and smell fresh when they are put on to be worn. “Fresh” garments have either no odor, or a slight pleasant odor. Fresh garments show no stains or spots of soil, and no wrinkles or creases. Fresh garments also should have the texture and drape appropriate to the fabric, such as a crisp surface in the case of many cotton or linen garments or a soft drape in the case of many silk or rayon fabrics. The lines of a fresh garment should be smooth and not show bags or bulges at the knees, seat, or elbows.
[0003] After wearing one time, clothing may not be too dirty to wear again, but it may not look or smell desirably fresh. For example, the clothing may have picked up unwanted odors by proximity to cigarette smoke or another person's perfume. Or for another example, some parts of a garment may have been stretched out of proportion to the rest of the garment, as often happens at the knees of blue jeans or elbows of a long-sleeved knit shirt. Or for another example, the back of a skirt or front of slacks may be deeply wrinkled from sitting.
[0004] The two obvious alternatives are either to go ahead and wear the non-fresh garment, or to launder the garment before wearing it again. Potential disadvantages of wearing a garment known to be non-fresh are apparent.
[0005] Disadvantages of laundering a garment that is not truly dirty are several: the inconvenience of waiting for the garment to be ready to wear, the environmental and financial costs of laundering garments after each wearing or even after long storage, and the gradual damage to garments caused by the laundering process.
[0006] Washing and drying clothes frequently does as much damage to them as the actual wearing of them, especially in the case of fragile garments that are worn only in clean, safe surroundings. The detergents, bleach, or other additives to the washing process can change the color of the garment and weaken the fibers. Even contact with liquid water can harm certain garments by rinsing out some of the dye or by creating “water spots.”
[0007] The agitation of a washing machine or even of hand laundering causes mechanical damage such as weakening of threads, pulling of seams, and small tears. Being dried in a heated clothes dryer from a fully-wet state causes stiffening or shrinkage of some types of fiber and breakdown of others. Drying a full load of laundry in a dryer may require the garments to be exposed to heat in the range of 150 to 220 degrees F. for 45 minutes or more. Drying on a clothes line outdoors can result in mechanical damage by hanging heavy, wet garments with clothes pins and the sunlight may bleach some fabrics and cause others to yellow.
[0008] The lint that accumulates in washing machines and in dryers is evidence of the stress the garments have been put through. Clothes do need to be laundered when dirty, but it is wasteful to do so simply because they are not optimally fresh.
[0009] This, when possible, it is better for clothing not to be wet with liquid water. Steam is a gentler medium for de-wrinkling and odor removal, especially when used in a carefully controlled process. Unfortunately, special devices for using steam to freshen clothing are often expensive and may require lengthy hands-on time for the user.
[0010] There are various time-honored methods for restoring garments that are wrinkled, stretched, or have odor. Wrinkled clothing is often hung on a hanger and placed in a bathroom before a person takes a hot steamy shower. The disadvantage of this method is that is not very effective. It may relieve an overall rumpled appearance, but does not affect sharply creased wrinkles. Because gravity provides the straightening force, this method works best on very heavy garments such as wool coats.
[0011] Garments with unwanted odors may be hung in fresh, moving air so that the odor gradually dissipates. The disadvantage of this method is that it is very slow and uncertain. A garment that seems to smell fresh after a few days of airing may nevertheless release stale or mildewed odor during wear. If the material causing the odor has more affinity for the textile fiber than for air, no amount of airing will completely remove the odor.
[0012] Conventional freshening processes include commercial products, mainly various pads or sheets that hold a chemical compound for relaxing wrinkles in clothing, often with an additional deodorizing chemical. The treated pad or sheet is tumbled with the garments in need of freshening in a rotary dryer. These conventional processes are more effective against general wrinkling than hanging the garment in the bathroom, but are of very little value in returning stretched garments to their original shape.
[0013] Disadvantages of such treated pads or sheets include: the softening chemicals used are not effective for all fabrics and may damage or spot some fabrics; a long tumble in the dryer may be required, thus not saving much energy over actually laundering the garment; the softening chemicals may give a fabric that is intended to be crisp a less-desirable soft texture; and some persons are allergic or sensitive to softening or deodorizing chemicals and do not wish to use them.
[0014] Conventional sprays of deodorizing chemicals are intended to remove odors from garments. The deodorant is sprayed on to the garment and the garment must hang in fresh air until the spray dries. Such sprays may leave behind a tell-tale odor themselves, which may be nearly as undesirable as wearing the non-fresh garment without treatment. Deodorant chemicals can leave temporary spots even on washable garments. These sprays are not effective against wrinkled or stretched garments.
[0015] Similarly, sprays of relaxing chemicals are applied to garments, which are then stretched and pulled to release the wrinkles. This pulling on the fabric tends to stretch the entire garment, rather than return it to its original size and shape.
[0016] Such sprays do not deodorize garments. If wrinkle relaxing and deodorizing chemicals were combined, the resultant spray would still not help stretched-out garments.
[0017] A very popular and traditional method of restoring non-fresh garments is to tumble them in a heated clothes dryer along with a dampened bath towel, that is, a sheet of terry cloth or “Turkish toweling” that is around 30 by 60 inches. The water in the towel becomes steam in the heated dryer and the steam encourages the fibers of the garment to return to their original locations in the weave or knit of the textile. It is hoped the steam will also carry away a portion of unwanted odors.
[0018] One disadvantage of this “bath towel” method is that if the towel is dripping wet, the process takes a long time. The garment is itself moistened by the water escaping the towel, and the garment needs to be re-dried. This longer drying time may be inconvenient for a person in a hurry and it causes increased wear damage to the garment. The dripping water can cause water spotting on susceptible fabrics.
[0019] The degree of deodorizing and de-wrinkling achieved with the bath towel method is slight, at best. Also, if a long tumble with heat is needed to achieve the desired results, certain stains or odors may be “set in” and made difficult to remove even with conventional laundering.
[0020] Another disadvantage of the bath towel method of restoring non-fresh clothes is that soaking, then wringing out, a standard bath towel is an awkward job, even beyond the strength of some people.
[0021] Further disadvantages include that bath towels tend to lose lint in the dryer, which may stick to the garment supposedly being made ready for wear; that using towels in this manner damages the towels; that a wet bath towel tends to roll into a ball in the dryer such that steam is liberated slowly; the loops of a cotton bath towel's pile do not provide any cleaning action; and that an ordinary bath towel does not necessarily hold enough water to accomplish the desired degree of treatment.
[0022] Therefore, it is apparent that a good method of “refreshening” garments is needed, by which is meant a method for restoring non-fresh clothing to wearability. Such a method should be safe and do little or no damage to most fabrics; should save substantial water, cost, and energy compared to conventional laundering; should be reliably effective and quick; should be convenient and easy for anyone to use; and should not use chemicals that cause allergy or irritation. Further, a method of refreshening garments should address wrinkles, stretching out, and odor because all these conditions often require remediation before a non-fresh garment should be worn.
SUMMARY OF THE INVENTION
[0023] The present invention is a method for refreshening garments, which makes use of a specialized “refreshening sheet.” The method of refreshening garments is intended to make non-fresh, but not heavily soiled, garments fresh enough to wear again.
[0024] The preferred embodiment of the refreshening sheet of the present invention is a flat sheet of microfiber textile with a long pile texture on one side. The sheet is about 76 cm by 76 cm in area with a density of about 300 grams per square meter.
[0025] The microfiber textile is similar to that often used for detailing autos, but less dense. The textile material preferably does not include surfactant, fabric softener, or any other additive that can be dissolved in water or rub off onto the garments to be refreshed.
[0026] To practice the method of the present invention, articles of dry clothing are placed in a rotary dryer. The refreshening sheet is saturated with clean water such that it is very moist but water does not drip out.
[0027] The moist refreshening sheet is then spread over the dry garments in the dryer. The dryer is turned on to allow the garments to tumble with the refreshening sheet in a temperature of 150 to 220 degrees Fahrenheit, or what is typically found in a dryer on “high” temperature setting. The water in the moist refreshening sheet is evaporated into the atmosphere inside the dryer to create a uniformly hot steamy environment around the garments.
[0028] The combination of warm steamy air and the massaging action of the refreshening sheet remove odors, superficial dirt, wrinkles, and return stretched out portions to their original shape within about 15 minutes.
[0029] Other features and many attendant advantages of the invention will become more apparent upon a reading of the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention is a method for using a “refreshening sheet” to refreshen garments or other fabric articles. The method of refreshening garments is intended to make non-fresh, but not heavily soiled, garments fresh enough to wear again.
[0031] The method makes use of a specialized refreshening sheet that carries a large load of water for generating steam, and that is composed of a blend of microfibers in a preferred weave for massaging the garments.
[0032] The sheet is composed of a microfiber textile with a deep pile texture on one side. By “microfiber” is meant a textile made up of fibers that are less than one denier. The fibers used to produce the sort of pile fabric of the preset invention are often multiply slit lengthwise, with other fibers inserted into the slits, as is known in the art. Because the added fibers do not fit perfectly into the slits, this leads to fibers that are intrinsically porous, that is, having interior voids. Also, it produces fibers that have lengthwise “ribs” that produce a mild degree of abrasiveness.
[0033] The nominal composition is 75% polyester and 25% polyamide.
[0034] Portions of the fibers are looped above the main woven body of the fabric, creating a long pile texture on one side of the refreshening sheet. In the preferred embodiment of the refreshening sheet of the invention, the elongate loops making up the pile are about 4-5 millimeters in length. Each loop is one yarn composed of many microfibers bundled together, but not twisted tightly into a thread. Thus, the loops have a much fuzzier profile than the loops of Turkish toweling. Each loop is itself a simple loop, not further twisted as in the case of Turkish toweling.
[0035] The opposite side of the refreshening sheet, in an exemplary embodiment, has a short nap texture, that is, is made up of loops about 1 mm in length.
[0036] The refreshening sheet is hemmed or otherwise finished around the periphery to stop the edges from raveling.
[0037] The density of the weave (thread count) and the length of the pile filaments combine to yield a mass-per-area density of 300 grams per square meter (gsm) for the textile of the preferred embodiment. This density of microfiber sheet allows a bit of light to pass through when it is held up before a light source such as a light bulb. Microfiber textiles with densities raging from 200 to 400 gsm were tested in the development of the present invention and 300 gsm was found to be optimal.
[0038] The refreshening sheet is able to hold about seven times its own mass in water without dripping, due to the high surface area created by the pile texture and the microporosity of the individual microfibers. By “hold water without dripping” is meant that water does not readily drip from the saturated refreshening sheet either by the force of gravity or by the mild squeezing force exerted such as by holding the refreshening sheet in the hands.
[0039] By distinction, cotton towels made of Turkish toweling, also known as terry cloth, typically have a density of 500 to 600 gsm, with especially luxurious towels having even greater densities.
[0040] Terry cloth towels are composed of long-staple cotton fibers, such as Egyptian cotton, which is believed to have a smooth silky feel and sheen. Examined closely, each loop of the toweling pile is a smooth thread formed into a loop that is twisted three or four times.
[0041] Somewhat contrarily to the absorbing function of a towel, the long smooth fibers of long-staple cotton are not especially intrinsically absorbent. However, for the function of rubbing wet sensitive skin, the smooth fibers are desirable. This is why cotton Turkish towels typically are large and have high density.
[0042] A bath-sized Turkish towel thus weighs a pound and a half or two when dry, and perhaps double that when wet. The refreshening sheet, in contrast, weighs only a few ounces dry and perhaps three pounds wet.
[0043] Conventional cotton terry cloth towels glide over most person's skin smoothly without abrasion or snagging. By contrast, the refreshening sheet is made up of such fine fibers that it snags and catches on otherwise-unnoticed roughnesses of the skin. This property would be quite annoying if the refreshening sheet were used for drying a person's skin, but this tendency to cling to microscopic features is desirable when the refreshening sheet is used according to the present method.
[0044] To practice the method of the present invention, articles of dry clothing are placed in the drum of a conventional rotary dryer with electric or gas heating. It has been found that three typical garments, such as shirts, pants, or skirts, is a preferred amount of loading to use with one refreshening sheet (of the preferred dimensions of 30 inches by 30 inches) in a standard household dryer. It is envisioned but not yet proven that larger loadings may be refreshened satisfactorily by using multiple refreshening sheets or a single sheet of greater area, particularly in a commercial-sized rotary dryer.
[0045] The refreshening sheet is saturated with clean water such that it is very moist but water does not drip out. This may be done by submersing the refreshening sheet in water, such as in a sink or dishpan, or by running water from a faucet over the refreshening sheet while squeezing the refreshening sheet. Then, the excess water is removed by gently lightly squeezing or wringing the refreshening sheet while holding the sheet out of the standing or running water.
[0046] The refreshening sheet should be held a few moments to ensure that water does not drip out. If excess water drips, the refreshening sheet should be squeezed or wrung again. However, it is not necessary or desirable that the refreshening sheet be squeezed or wrung out with great force. This will remove too much water and possibly damage the microfibers.
[0047] The saturated refreshening sheet is then spread over the garments in the dryer. The dryer is activated such that the garments tumble with the refreshening sheet in the drum of the dryer in an air temperature of 150 to 220 degrees Fahrenheit, or what is typically found in a dryer on “high” temperature setting. The water initially held by the moist refreshening sheet is evaporated into the atmosphere inside the dryer to create a uniformly hot moist environment around the garments.
[0048] The heated tumbling is allowed to continue for 10 to 15 minutes to produce a desired degree of refreshening; but no longer than 25 minutes to avoid heat damage to the refreshening sheet or garments. Garments are preferably removed from the rotary dryer immediately at the end of the 10 to 15 minute process time and are folded, hung up, or worn.
[0049] The refreshening sheet should be fully air dried in ambient temperature after use. It should be washed by itself in mild detergent or soap, preferably after two uses, to remove accumulated odors or soil. The fibers making up the refreshening sheet will eventually degrade. The refreshening sheet must be replaced when it becomes ineffective.
[0050] The reason for spreading the refreshening sheet over the dry garments is twofold: first, so that the entire refreshening sheet is immediately available to the heat of the dryer in order to create a hot steamy atmosphere as quickly as possible, and secondly to assure that the refreshening sheet mingles and tumbles with the garments and is not rolled into a ball in the dryer.
[0051] It has been found by testing that a refreshening sheet composed of the microfiber textile, described in detail above, is fairly resistant to becoming wadded into a ball, as compared to conventional Turkish towels. It is believed that this is partly due to the 300 grams per square meter (gsm) density that allows passage of air through the pile and partly due to the mild abrasive quality of the microfibers, which causes the refreshening sheet to cling very slightly to the garments. A strong clinging force between refreshening sheet and garments is not desirable, because the refreshening sheet might cling to single garment the entire process cycle instead of moving from one garment to another.
[0052] Thus, the initial spreading of the refreshening sheet is sufficient to ensure that the refreshening sheet does not ball up. By contrast, if one tries to practice this method with a wet Turkish towel, the towel is very likely to ball up and simply agitate back and forth in the bottom of the drum of the rotary dryer instead of tumbling among the garments as the drum rotates. The failure of Turkish toweling to tumble well is believed to be due to the density of the Turkish toweling and the smoothness of the cotton fibers.
[0053] The refreshening sheet tumbles with the garments and the pile filaments stroke the surfaces of the garments, pulling away odors and slight soil. Microfibers have greater surface area and are internally porous, as compared to conventional textile fibers. The foreign materials on the garments that are responsible for odors or visible spots will be drawn toward the microfiber and sequestered.
[0054] Textiles of the same fiber composition but different density were found to vary greatly in their performance of the function of refreshening garments. Textile sheets with a density around 300 gsm allowed conversion of most of their retained water into steam within an exemplary 12-minute cycle of tumbling in a heated dryer but were still very hot and steamy at the end of the 12-minute cycle.
[0055] Sheets with a density of 325 gsm or higher did not allow heated air to flow through sufficiently. Production of steam and temperature of the sheet after a 12-minute cycle decreased with increasing density. Sheets were still wet at the end of the 12-minute cycle and not much steam was present in the drum of the rotary dryer.
[0056] Sheets with a density of 275 gsm or less dried out too quickly. Retained water and steam in the dryer drum were gone before the end of a 12-minute cycle and the sheet was not hot. The steam did not last long enough, so the refreshening function was performed poorly.
[0057] It has been found that 10 to 15 minutes is the preferred duration of the tumbling in a heated dryer portion of the method of the present invention. For example, 12 minutes of heated tumbling is effective at refreshening most garments but does not produce undue damage to the refreshening sheet or garments.
[0058] Because a relatively low density of 300 grams per square meter (gsm) is the most effective for practicing the method of the present invention, it is clear why cotton towels are not very good for refreshening garments. A cotton towel of this density would have to be impractically large in area to hold sufficient water to generate a large amount of steam for 12 minutes. A cotton towel large enough would fill the dryer drum on its own, leaving no room for garments.
[0059] A more conventional bath towel of at least 600 gsm does not allow passage of hot air, thus releases its retained water as steam too slowly to perform the refreshening function.
[0060] Although particular embodiments of the invention have been illustrated and described, various changes may be made in the form, composition, construction, and use of the refreshening sheet herein without sacrificing any of its advantages. Therefore, it is to be understood that all matter herein is to be interpreted as illustrative and not in any limiting sense, and it is intended to cover in the appended claims such modifications as come within the true spirit and scope of the invention. | Refreshening sheet and method for using it to restore stretched, wrinkled, or odorous garments to wearability without actual laundering. Sheet is a polyester/polyamide microfiber textile sheet with long loop pile on one side and density of 300 grams per square meter. Refreshening sheet is saturated with plain water and tumbled in a rotary dryer along with dry garments for ten to twenty minutes. The refreshening is accomplished by the generated steam and the massaging action of the slightly abrasive loops. | 3 |
This application is a division of application Ser. No. 09/175,367, filed on Oct. 20, 1998, now U.S. Pat. No. 6,306,476.
BACKGROUND TO THE INVENTION
1. Field of the Invention
The present invention relates to self-adhesive labels and to a method of producing self-adhesive labels. In particular, the present invention relates to self-adhesive labels of multilaminar construction in which the label incorporates a booklet or folded sheet so as to provide a large surface area for carrying printed information which is greater than the surface area of the footprint of the label. The labels of the present invention have particular application in the labelling of pharmaceutical products.
2. Discussion of the Prior Art
A variety of so-called leaflet labels or booklet labels are known in the art and a typical label construction is disclosed in U.S. Pat. No. 5,399,403 in the name of David J. Instance. It is well known for the folded Leaflet or booklet to be overlaminated with a self-adhesive transparent plastics layer. The overlaminate provides durability to the label against inadvertent damage or tearing and also improves the aesthetic appearance of the label. Furthermore, the overlaminate can provide a structural part of the label to enable the leaflet or booklet label to be opened from a closed configuration by pulling the overlaminate away from a surface of a product, such as a pharmaceutical container, which is labelled to enable the leaflet or booklet to be read by a user. In some labels, the overlaminate can be re-adhered to the product to return the label to its closed configuration. Typical plastics materials for use as the overlaminate include oriented polypropylene carrying a pressure-sensitive adhesive on its rear surface.
U.S. Pat. No. 4,529,229 discloses a self-adhesive label in which an adhesive strip is provided to retain a folded strip in its folded configuration by being adhered to a top label and an underlying panel of the strip.
when pharmaceutical products are labelled, it is often necessary for the label to be printed with specific information, such as a lot of batch code and an expiry date. Such printing is generally achieved by providing a generic printed label for a particular pharmaceutical product and then overprinting a series of the labels with the required batch or lot code and expiry date.
A technical problem exists in the art in that there is a need to provide on overlaminated leaflet or booklet labels an area which is suitable for being printed with high quality alphanumeric printing devices suitable for printing batch codes, expiry dates and the like. There is also a need in the art for such overlaminated labels, particularly for pharmaceutical products, to be overprinted with bar codes which contain information relating to the overprinted batch codes, expiry dates, etc. and act as a security feature which can be scanned automatically to check that the required overprinting has been effected. The bar code needs to be small in area yet accurately printed in order to be machine readable at high speeds.
When information is overprinted onto paper, i.e. when a non-overlaminated leaflet or booklet label is being printed, ink is printed onto the paper surface of the label and then a laser is employed either to vaporise some of the ink so as to leave white lettering surrounded by the ink or to burn the lettering into the surface of the paper. The present inventor has attempted to replicate this laser printing process onto a plastics overlaminate, in particular an oriented polypropylene self-adhesive laminate. However, following laser treatment the appearance of the printing is poor because the laminate tends to have a bubble effect imparted thereto by the laser, which the present inventor believes results from vapours being emitted from the paper surface and thermal distortion of the plastics laminate. In addition, it is believed that the overlaminate absorbs some of the energy from the laser which may require the utilisation of a relatively powerful laser, or a longer burn time, which may in turn exacerbate the bubbling problem.
The present inventor has also attempted to overprint onto a plastics overlaminate by using a thermal transfer printer. Such thermal transfer printers use a multi-element print head with a large number of tiny heating elements that can be turned on and off in a desired pattern or configuration under computer control so as to print selected alphanumeric characters. A ribbon is pressed between the print head and the substrate to be printed and when the print head elements are turned on so as to become heated, the elements soften the coating on the surface of the ribbon in contact with the substrate allowing the coating to stick to the substrate as a pattern of dots. The desired alphanumeric symbols to be printed are of course controlled by selectively activating the desired pattern of heating elements. The present inventor has discovered that the plastics overlaminate surface tends not to be receptive to some thermal transfer coatings.
There is also a desire to overprint by means of wet printing. In wet printing a liquid vehicle of a wet printing ink dries by absorption into the printed substrate. This is not possible with a plastics overlaminate because the vehicle cannot absorb thereinto, leading to smudging of the printed image.
These problems have been solved in the prior art by adhering a self-adhesive overlabel to the upper surface of the overlaminate, which overlabel has an upper surface which can be printed on by at least one of laser printing and thermal transfer printing. Such a construction is disclosed in WO98/07133 in the name of David J Instance Limited. However, this solution necessarily results in increased material costs due to the need to provide extra material for the overlabel and increased production costs due to the need for an extra production step to apply the overlabel to the upper surface of the overlaminate.
WO 97/04433, WO98/07131 and WO98/07132 disclose other types of over-laminated leaflet labels
It is therefore an object of the present invention to at least partially solve these problems of the prior art.
SUMMARY OF THE INVENTION
The present invention provides a self-adhesive label carried on a backing of release material, the label comprising;
a self-adhesive support piece which is releasably adhered to the backing;
a multi-laminar label portion adhered to a first portion of an upper surface of the support piece, a second portion of the upper surface of the support piece adjacent the first portion being left uncovered by the multi-laminar label portion; and
a self adhesive over-laminate adhered to an upper surface of the multi-laminar label portion so as substantially to cover the multi-laminar label portion and to a portion of the hacking of release material adjacent to the multi-laminar label portion thereby to retain the multi-laminar label portion in a closed configuration, and wherein the second portion of the upper surface of the support piece is left substantially uncovered by the over-laminate.
The ability to efficiently produce labels in large numbers is often an important requirement- It is therefore a further object of the present invention to provide a method for producing a succession of self-adhesive labels according to the present invention by which large numbers of self-adhesive labels according to the present invention can be produced efficiently with a minimum number of production steps.
The present invention therefore further provides a method for producing a succession of self-adhesive labels carried on a backing of release material according to the present invention, said method comprising the steps of;
at providing an elongate web comprising a self-adhesive support web having a backing of release material;
b) die-cutting and removing from the backing of release material a succession of portions of the support web to leave a succession of intermediate parts of the support web longitudinally spaced along the backing of release material;
c) adhering a succession of multi-laminar label portions to the succession of intermediate parts of the support web, each multi-laminar label portion being adhered to a first portion of an upper surface of the respective intermediate part of the support web, a second portion of the upper surface of the intermediate part of the support web adjacent to the first portion being left uncovered by the multi-laminar label portion; and
d) adhering a succession of portions of a self-adhesive over-laminate to the upper surface of the succession of multi-laminar label portions so that each portion of the over-laminate substantially covers the respective multi-laminar label portion and a respective portion of the backing of release material which is adjacent to the respective multi-laminar label portion thereby to retain the multi-laminar label portion in a closed configuration, the second portion of the upper surface of each intermediate part of the support web being left substantially uncovered by the over-laminate.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 shows a perspective view of a self-adhesive label according to a first embodiment of the present invention
FIG. 2 shows a side view of a self-adhesive label according to a second embodiment of the present invention.
FIG. 3 shows an overhead view of a succession of self-adhesive labels according to a third embodiment of the present invention in an intermediate stage of their production according to a method of the present invention.
FIG. 4 shows a cross-section of a self-adhesive label shown in FIG. 3 after final die-cutting taken through line A—A— in FIG. 3 .
FIG. 5 shows a cross-section of a self-adhesive label shown in FIG. 3 after final die-cutting taken through line B—B in FIG. 3 .
FIG. 6 shows a perspective view of a self-adhesive label according to a fourth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a perspective view of a self-adhesive label according to a first embodiment of the present invention. The self-adhesive label, designated generally as 2 , comprises an underlying support piece 4 which is adhered to a web of release backing material 6 by a layer of pressure-sensitive adhesive a on the rear surface thereof.
A booklet 10 is adhered to a first portion of the support piece 4 adjacent transverse edge 12 by a layer of permanent adhesive 14 . A plastic transparent over-laminate 16 is adhered to the upper surface 18 of the booklet 10 by its underlying layer of pressure-sensitive adhesive 26 . The left transverse edge 20 of the over-laminate coincides with the spine 22 of the booklet 10 .
The portion 28 of the upper surface of the Support piece adjacent the left transverse edge 24 thereof id left uncovered by both the booklet 10 and the over-laminate 16 and is therefore available for being printed on by, for example, laser printing or thermal transfer printing.
The over-laminate 16 has a region 30 which is adhered directly to the release backing material 6 . This region 30 of the overlaminate 16 ensures that the booklet 10 is held in its folded configuration by the adhesion of the over-laminate region 30 to the release backing material 6 .
In use, the self-adhesive label is adhered to the surface of a product to be labelled, typically a curved container. When it is desired to open the label, a user manually peels the region 30 of the over-laminate 16 which is releaseably adhered to the container surface away from the surface of the container so that the booklet 10 may be opened and read by a user. After use, the label may be returned to its closed configuration by adhering the over-laminate region 30 again by its self-adhesive surface to the container.
Referring to FIG. 2, there is shown a side-view of a self-adhesive label according to a second embodiment of the present invention. This self-adhesive label is identical to that shown in FIG. 1 except that a leaflet 110 is employed instead of a booklet.
Next, a method of producing a succession of self-adhesive labels according to a third embodiment of the present invention shall be described with reference to FIG. 3 and FIGS. 4 and 5.
An elongate web 300 comprising a support web releaseably adhered to a backing of release material 206 by a layer of pressure-sensitive adhesive 208 on the underlying surface thereof. A longitudinal section of the elongate web 300 is shown in FIG. 3 . In a first step, the support web is die-cut without cutting through the backing of release material. A succession of transverse columns of rectangular shapes 302 is cut into the support web, and the portions of the support web defined by these shapes are removed from the backing simultaneously with die-cutting to leave a succession of three-up columns of rectangular windows 304 in the support web through which the backing of release material 206 is exposed. As will be evident to the skilled person, the portions of support web defined by the rectangular shapes 302 could also be removed in a separate step after die-cutting.
It will also be apparent to the skilled person that the rectangular windows 304 do not have to be arranged in transverse columns of three as shown in the drawings, but could alternatively be arranged in columns of any other number depending, amongst other things, on the size of the resultant labels.
The left edge 306 of each rectangular window 304 formed in the support web defines the right transverse edge of an intermediate part ( 350 ) of the support web, and the right edge 308 of each rectangular window 304 defines the left transverse edge 224 of an adjacent intermediate part ( 350 ) of the support web. Each column of rectangular windows 304 therefore defines the right transverse edge of a transverse column of three intermediate parts ( 350 ) of the support web, and the left transverse edge of an adjacent transverse column of three intermediate parts ( 350 ) of the support web.
The term “intermediate part” refers to the portion of the support web which will form the support piece ( 204 ) in the respective final label. At this stage of production, in this preferred embodiment of the method of the present invention the intermediate parts are connected in the transverse direction by interconnecting portions of the support web, and are only separated from each other in the final die-cutting step which is described below.
A gutter 310 of support web is left between each rectangular window 304 in any transverse column.
The next step is to apply a succession of booklet strips 312 to the support web, one booklet strip 312 for each transverse column of intermediate parts ( 350 ) of the support web. The outline of the booklet strips 312 is shown by the short-dash line in FIG. 3 . Since the intermediate parts ( 350 ) are arranged in transverse columns of three, each booklet strip 312 also comprises a continuous strip of three booklets 210 , one for each intermediate part ( 350 ) in a single column. Each booklet strip is arranged on the support web such that each individual booklet 210 in the booklet strip 3312 lines up with the respective intermediate part ( 350 ) in the respective transverse column, and such that the right edge 314 of the upper sheet of the booklet strip 312 extends partially over the rectangular windows 304 created in the support web. Each booklet strip 312 is applied to the support web by a layer of permanent adhesive 214 . The booklet strips 312 are of such width that they do not occupy the whole area of the upper surface of the intermediate parts ( 350 ) in the respective transverse column but leave a left-hand portion 228 of the upper surface of each intermediate part 350 in the respective transverse column uncovered.
The upper sheet of each booklet composing the booklet strip is provided with a tab portion 340 protruding from its right edge 316 and extending over the respective rectangular window 304 formed in the support web Par of this tab portion 340 remains as a tab 240 in the finished label and facilitates the opening of each booklet 210 in the finished label.
Although not a feature of the embodiment shown in the Figures, the booklet strip can be folded in half widthwise before applying it to the support web by doing so, the area occupied by each booklet on the respective support piece in the final label can be reduced by half, whereby a support piece of reduced area can be employed, or the area of the support piece available for subsequent printing can be increased for a support piece of given area.
The next step is to apply a succession of transverse strips 318 of self-adhesive transparent plastics over-laminate, one for each booklet strip 312 . A transverse strip 318 of specified width is applied over the full length of each booklet strip 312 and adhered to the upper surface of the respective booklet strip 312 by its underlying layer of pressure-sensitive adhesive 226 . The outline of the over-laminate strips 318 are shown by the long-dash lines in FIG. 3 . Each over-laminate strip 318 is arranged on the respective booklet strip such that its right transverse edge 320 finishes approximately level with the right edge 322 of the tab portions 340 protruding from the upper sheet of the respective booklet strip 312 . The width of the overlaminate strip 318 is such that its left edge 324 lies slightly to the right of the spine 326 of the booklet strip 312 .
The final step is to die-cut along the U-shaped line shown by the crossed-line in FIG. 3 . The final cut die thus cuts through the booklet strip 312 and overlaminate strip 318 , as well as through the support web to define the top and bottom longitudinal edges of each label, and cuts though the booklet strip 312 and overlaminate strip 318 to define the right transverse edge of each label.
The corners of the U-shaped die are rounded whereby the top-right right and bottom-right corners of each resultant label are also rounded.
The right-hand edge 308 of each rectangular window 304 that was originally cut out of the support web becomes the left edge 224 of the respective finished label. There is therefore no support web between the left and right transverse edges of longitudinally adjacent labels that has to be taken up with the unwanted matrix of support web.
The longitudinally-extending gutters 310 of support web left deliberately between the rectangular windows 304 la the pre-die-cutting step have the result that the matrix of waste support web to be removed from the backing of release material is continuous in the longitudinal direction and can therefore be removed easily from the backing of release material. This removal of the waste matrix is further facilitated by the reinforcing effect of the over-laminate on these sections of the support web.
The portion 228 of the upper surface of each label to the left of the spine 222 of its booklet 2310 remains uncovered by the overlaminate 216 t is therefore available for laser coding or another alternative method of printing such as thermal transfer printing without the need to apply an overlabel.
The resultant self-adhesive label after final die-cutting is shown in FIGS. 4 and 5 as cross-sections taken through line A—A— and line B—B of FIG. 3, respectively.
In use, the self-adhesive label is adhered to the surface of a product to be labelled, typically a curved container When it is desired to open the label, a user manually grabs the tab 240 which is not adhered to the container surface directly and the tab 240 is pulled away from the container thereby to pull the over-laminate region away from adhesive contact with the surface of the container so that the booklet 210 may be opened and read by a user. After use, the label may be returned to its closed configuration by adhering the over-laminate region 230 again by its self-adhesive surface to the container.
Referring to FIG. 6, there is shown a perspective view of a self-adhesive label according to a fourth embodiment of the present invention. This self-adhesive label is similar to that shown in FIG. 1 . However, in this embodiment, the booklet 410 is arranged on the first portion of the upper surface of the support piece 404 adjacent transverse edge 412 in art unfolded configuration (the spine of the booklet is shown by the dashed line 440 ) and is only temporarily held on the first portion of the upper surf ace of the support piece 404 by a layer of a removable adhesive 414 . The plastic transparent overlaminate 416 is adhered to the upper surface 418 of the unfolded booklet 4310 , and extends beyond the left transverse edge of the unfolded booklet 410 such that a region of the overlaminate 416 is adhered to a part of the second portion 428 of the support piece 404 uncovered by the booklet 410 whilst still leaving a substantial part of the second portion 428 of the support piece 404 uncovered by both the booklet 410 and overlaminate 416 , and therefore available for subsequent printing. The overlaminate 4316 is adhered to the second portion 428 of the support piece to an extent sufficient to securely hold the booklet 410 /overlaminate 416 assembly on the support piece 404 .
In use, the self-adhesive label is adhered to the surface of a product to be labelled, usually a curved container. When it is desired to open the label, a user manually peels the region 430 of the overlaminate 416 which is releasably adhered to the container surface away from the surface of the container, and also lifts the unfolded booklet 410 from the first portion of the upper surface of the support piece 404 so that the pages of the booklet 4101 can be turned and read. After use, the label is returned to its closed configuration by adhering the overlaminate region 430 again by its self-adhesive surface to the container.
In this embodiment, the booklet 4101 is only permanently attached to the support piece 404 via the overlaminate 416 . The adhesion of the overlaminate to the second portion 428 of the support piece 404 therefore prevents the left edge of the booklet from falling open when the label is closed and prevents the booklet from becoming completely detached from the label when the label is opened.
As will be clear to the skilled person, the layer of removable adhesive 4314 shown in FIG. 6 only serves to temporarily hold the unfolded booklet 410 in place on the support piece 404 until the overlaminate 4116 is applied in view of this function of the layer of removable adhesive 414 , it will also be clear to the skilled person that it is equally possible to alternatively use only a couple of dots of removable adhesive to temporarily adhere the unfolded booklet 410 to the first portion of the upper surface of the support piece 404 , or to provide the temporary adhesion by means of electrostatic charge or some similar transitory mechanism rather than by using a removable adhesive In fact, this will be advantageous since the booklet 410 will be more readily liftable from the first portion of the support piece when the label is opened to read the booklet.
A succession of the above-described self-adhesive labels according to the fourth embodiment can be produced by the method described earlier with appropriate modifications thereto in accordance with the modifications in construction. | A method of producing a succession of self-adhesive labels carried on a backing of release material including the steps of; a) providing an elongate web comprising a self-adhesive support web having a backing of release material; b) die-cutting and removing from the backing of release material a succession of portions of the support web; c) adhering a succession of multilaminar label portions to the succession of intermediate parts of the support web; and d) adhering a succession of portions of a self-adhesive overlaminate to the upper surface of the succession of multilaminar label portions so that each portion of the overlaminate substantially covers the respective multilaminar label portion and a respective portion of the backing of release material which is adjacent to the respective multilaminar label portion, the second portion of the upper surface of each intermediate part of the support web being left substantially uncovered by the overlaminate. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a pigment composition for coloring. Specifically, it relates to a colorant formed of a phthalocyanine pigment as a main coloring ingredient and a plastic molded article which is colored with the above colorant and is small in warpage or deformation.
PRIOR ARTS OF THE INVENTION
[0002] Phthalocyanine pigments used as a colorant for a plastic have characteristic features such as light resistance, heat resistance, resistance to transferability, a clear hue and high tinting strength. However, when the phthalocyanine pigment is used for coloring a thermoplastic resin which has crystallinity partially, such as polyolefin or polyethylene terephthalate, the phthalocyanine pigment exerts an influence upon the crystallinity or crystallization direction of the resin during molding. As a result, a plastic molded article warps or deforms. It is thought that this is because the phthalocyanine pigment works as a crystallizing agent for the resin.
[0003] For improving the warpage or deformation of a plastic molded article, molding makers are aiming at optimization by changing processing conditions such as a molding temperature, an injection pressure, an injection time, an injection speed or a cooling time. However, a contraction coefficient differs depending upon the kind of a resin, a colorant, an additive and the size or shape of a molded article so that it is difficult to set processing conditions in consideration of warpage or deformation. In many cases, the cycle of molding is lengthened, which worsens productivity.
[0004] As another means for improving the warpage or deformation, a strong crystallizing agent (a crystalline nucleus agent, a nucleus-forming agent or a crystallization accelerating agent) is added. The addition of the crystallizing agent has a function of rapidly generating a fine crystal since a component to become a crystalline nucleus is added in a large amount. Seemingly, it has an effect of decreasing the influence of the phthalocyanine pigment upon contraction. Further, it is known that the use of the crystallizing agent can shorten the cycle of molding and bring about an improvement in stiffness or transparency. As a crystallizing agent, for example, there is used a metal carboxylate such as sodium benzoate, 4-tert-butyl aluminum benzoate or sodium adipate, an acid metal phosphate such as sodium bis(4-tert-butylphenyl)phosphate or sodium-2,2′-methylenebis(4,6-di-tert-butylpheynl)phosphate, or a sorbitol acetal type agent such as dibenzylidene sorbitol or bis (methylbenzylidene) sorbitol. However, the crystallizing agent has an insufficient effect on the warpage or deformation.
[0005] Further, methods in which a pigment is modified so as not to work as a crystalline nucleus have been studied. Attempts are carried out to change the crystal form, particle diameter or shape of a pigment, to modify the surface of a pigment by adding a pigment derivative (organic coloring matter compound) obtained by introducing a variety of substituents into a pigment skeleton and to modify the surface of a pigment by surface-treating the pigment with a resin or a silane-coupling agent.
[0006] JP-A-04-376232, JP-A-57-155242 and JP-A-58-125752 disclose methods which change the crystal form, particle diameter or shape of a pigment. However, none of them obtains a sufficient effect. Further, a change in the crystal form, particle diameter or shape of the pigment exerts an influence upon the inherent properties of the pigment, such as a hue, dispersibility, tinting strength, heat resistance and light resistance.
[0007] As a method for improving the warpage or deformation of the phthalocyanine pigment, there is a method disclosed in Journal of the Japan Society of Colour Material (2003), Vol. 76, p. 97, in which a specific number of halogen atom(s) are introduced into a phthalocyanine structure. This method improves the warpage or deformation but extinguishes the inherent properties of the phthalocyanine pigment such as high tinting strength or high clearness and also changes its hue largely.
[0008] As a method of modifying a pigment surface by using a so-called pigment derivative obtained by introducing a substituent into a pigment structure for the purpose of improving warpage or deformation, JP-A-53-7185 and JP-A-03-12432 disclose phthalimide methyl derivatives. This invention improves the warpage or deformation to some extent. However, the improvement is not sufficient. Moreover, when the pigment derivative is added in an amount required for improving the warpage, color transferability worsens, so that the above method has not yet applied to practical use.
[0009] As a method of modifying a pigment surface with a material other than the pigment derivative, a surface-treatment with an organic silane or an organic titanium and a surface coating of a pigment with a thermoplastic resin are carried out. JP-A-05-194873 discloses that a pigment surface is modified with a polymer formed of a water-soluble high-molecular ammonium salt in the copresence of a sulfonic acid having an organic pigment residue and the polymer. However, the effect is insufficient in each method.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a pigment composition containing a phthalocyanine which pigment composition, when used for coloring a plastic, can give a molded article free from warpage or deformation without impairing excellent properties of the phthalocyanine as a colorant, and a colorant obtained therefrom.
[0011] According to the present invention, there is provided a pigment composition composed of 50 to 95% by weight of a phthalocyanine, 1 to 45% by weight of a halogenated phthalocyanine of which the number of substituents of a halogen atom is 1 to 9 and the average number of the substituents is 2.0 to 4.0, and 0.1 to 10% by weight of a phthalocyanine derivative represented by the formula (1) or the formula (2),
P-(X)m (1)
[0012] wherein P represents a phthalocyanine structure, X represents an alkyl group having 12 to 18 carbon atoms, an alkoxy group having 12 to 18 carbon atoms, —SO 2 NHR, —SO 2 NR 2 , —NR 2 , —CONR 2 , —CONHR or —SR (wherein R represents an alkyl group having 12 to 18 carbon atoms or an alkenyl group having 12 to 18 carbon atoms), and m is an integer of 1 to 4,
[0013] wherein P represents a phthalocyanine structure, Y is a hydrogen atom or a halogen atom, and n is an integer of 1 to 4.
[0014] According to the present invention, further, there is provided a colorant for a plastic formed of the above pigment composition.
[0015] According to the present invention, further, there is provided a powdery colorant composed of the above pigment composition and an aliphatic metal carboxylate or an aromatic metal carboxylate.
[0016] According to the present invention, further, there is provided a colorant obtained by compounding the above pigment composition at a high concentration with a plastic.
[0017] According to the present invention, further, there is provided a colorant according to the above, wherein the plastic is a polyolefin.
[0018] According to the present invention, further, there is provided a molded article obtained by compounding the colorant recited above with a plastic.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention will be explained in detail hereinafter. The phthalocyanine used in the present invention is a metal-free phthalocyanine or a metal phthalocyanine such as a copper phthalocyanine or an aluminum phthalocyanine. The presence or absence of a central metal and the kind of the phthalocyanine are not specially limited.
[0020] The same phthalocyanine as above may be used for the phthalocyanine structure (P) of the formula (1) or the formula (2) in the present invention.
[0021] The process for producing the halogenated phthalocyanine used in the present invention is selected from generally known production processes of halogenated phthalocyanines, and it is not specially limited so long as the number of substituents of a halogen atom is from 1 to 9 and the average number of the substituents is from 2.0 to 4.0. Examples of the production process include a production process in which a halogenated phthalic acid having a halogen atom substituent introduced therein is used to synthesize a crude halogenated phthalocyanine, an AlCl 3 /NaCl Process in which a halogen atom is introduced into a crude phthalocyanine in a molten salt of aluminum chloride or aluminum chloride and a common salt and a production process in which a halogenated phthalonitrile is used to synthesize a crude halogenated phthalocyanine. Of these, a halogenated phthalocyanine obtained by the AlCl 3 /NaCl Process is excellent in warpage-improvement effect over halogenated phthalocyanines obtained by the other processes, so that the AlCl 3 /NaCl Process is more preferable. The average number of halogen substituents is adjusted by controlling the amount of a halogen to be introduced. The amount of the halogen to be introduced defers depending upon production process, equipment and reaction conditions. When the halogen amount is small, the average number of halogen substituents is small. When the halogen amount is large, the average number of halogen substituents is large. When the halogen amount is too small, it is undesirable in view of warpage-improvement effect. When the halogen amount is too large, undesirably, the warpage improvement effect or hue is poor. The halogen amount is preferably adjusted such that the average number of halogen substituents becomes from 2.0 to 4.0.
[0022] The halogenated phthalocyanine may be used as it is, while it is preferred to convert the crystal form thereof into an amorphous form for further decreasing the behavior thereof as a nucleus agent. For example, the above conversion can be carried out by a known method such as a treatment by an acid pasting method using a sulfuric acid.
[0023] The form of the halogenated phthalocyanine is not limited in the present invention. The halogenated phthalocyanine can be used in the form of a powder or an aqueous paste according to a production process of a colorant or a master batch.
[0024] The content of the halogenated phthalocyanine in the pigment composition in the present invention is 1 to 45% by weight. The content of the halogenated phthalocyanine is more preferably 5 to 20% by weight in view of a hue. When the content of the halogenated phthalocyanine is small, undesirably, the effect of improving warpage is insufficient. When it is too large, undesirably, the clear hue of phthalocyanine is lost.
[0025] The phthalocyanine derivative of the formula (1) or the formula (2) can give a warpage-improving effect even when it is used alone. In this case, it is required that a pigment composition contains 10 to 20% by weight of the phthalocyanine derivative. When the phthalocyanine derivative is used in the above amount required for improving warpage, clearness or a hue worsens. For this reason, it is undesirable in practical use to use the phthalocyanine derivative singly.
[0026] The content of the phthalocyanine derivative used in the present invention in the pigment composition is preferably from 0.1 to 10% by weight, more preferably 0.1 to 4% by weight. When the content of the phthalocyanine derivative is too small, undesirably, the effect of improving clearness or warpage is insufficient. When it is larger than 10% by weight, undesirably, the hue is unclear.
[0027] When the halogenated phthalocyanine and the phthalocyanine derivative of the formula (1) or the formula (2), which constitute the pigment composition of the present invention, are concurrently used with a phthalocyanine pigment, the thus-obtained pigment composition shows a remarkably large effect of decreasing the warpage or deformation of a molded article when compared with a pigment composition obtained by using the halogenated phthalocyanine or the phthalocyanine derivative singly.
[0028] The method of mixing the phthalocyanine with the halogenated phthalocyanine and the phthalocyanine derivative of the formula (1) or the formula (2) is not specially limited. Examples of the mixing method include a method in which powders of these are mixed with a mixing apparatus such as a three-hands mixer, a Henschel mixer, a tumbler or a Nauta mixer, a method in which these components are stirred and mixed in the form of slurries in water or organic solvents, a method in which these components are kneaded with a three-roll mill or a two-roll mill in the presence of a medium, and a method in which the halogenated phthalocyanine and the phthalocyanine derivative of the formula (1) or the formula (2) are added in a pigmentation step such as a kneading step or a solvent treatment step. Preferably, the method in which the above components are mixed in the form of slurries in organic solvents is advantageous in terms of exerting a sufficient effect.
[0029] The colorant for a plastic, provided by the present invention, may contain a component other than the pigment composition so long as it hampers the effect of the present invention or causes no sanitary problem. The component other than the pigment composition includes a different organic pigment, an inorganic pigment, a low-molecular-weight polyolefine or a derivative thereof, a heavy metal deactivator, a metallic soap of a metal such as an alkali metal, an alkaline earth metal or zinc, hydrotalcite, an antistatic agent such as a nonionic surface active agent, a cationic surface active agent, an anionic surface active agent or an ampholytic surface active agent, a flame retardant such as a halogen type flame retardant, a phosphorus type flame retardant or a metal oxide, a lubricant such as ethylenebis alkylamide, an antioxidant, an ultraviolet absorber, a processing aid, a filler, and a variety of known additives for a polymer. For satisfying the required quality and coloring workability, phthalocyanine pigment is dispersed with the above component(s) in advance. The colorant of the present invention is provided in the form of a powdery dry color, a granular bead color, a liquid paste color or a liquid color.
[0030] A preferable form of the colorant of the present invention is a dry color which is a powdery colorant containing a pigment at a high concentration. The dry color generally contains as a dispersing agent 1 to 1,000 parts by weight of an aliphatic carboxylic acid or an aromatic carboxylic acid and/or a metal salt of any one of these per 100 parts by weight of the total weight of the phthalocyanine, the halogenated phthalocyanine and the phthalocyanine derivative of the formula (1) or the formula (2). Examples of the aliphatic carboxylic acid include caprylic acid, oleic acid, stearic acid, etc. Examples of the aromatic carboxylic acid include phthalic acid, benzoic acid, etc. Examples of the metal include lithium, calcium, magnesium, zinc, etc. The dry color is in the form of powder and thus insufficient in workability. However, the dry color has a high pigment concentration and even a small amount of the dry color can serve for coloring. Therefore, the dry color is the most reasonable economically, so that it is used for coloring a polyolefin in many cases. When the dry color is used for molding, the amount of the dry color per 100 parts by weight of a plastic for the molding is 0.001 to 10 parts by weight. A pellet of plastic and the dry color are uniformly mixed with a mixer, etc., in advance, and then the mixture is subjected to molding processing.
[0031] In the present invention, the plastic to be colored is a resin which softens by heating and again hardens by cooling and which has crystallinity partially. Particularly, it includes homopolymers, blocks, or random copolymers or terpolymers of ethylene, propylene, butylene, styrene and/or divinylbenzene, and α-olefins such as HDPE, LDPE, polypropylene and polystyrene. Examples of other useful resins include polyesters such as polyethylene terephthalate, polyamides such as Nylon-6 and Nylon-66, and thermoplastic ionomers. The colorant of the present invention has a high effect on these thermoplastic resins having crystallinity. Particularly, the colorant of the present invention has a remarkable effect on a so-called polyolefin resin such as homopolymers or copolymers of α-olefin ethylene, propylene and butylene.
[0032] The polyolefin resin preferably has an MFR (melt flow rate) of 0.001 to 30. When the MFR is smaller than 0.001, undesirably, due to a too high melt viscosity of a coloring resin composition, molding processability worsens in some cases or an molded article has a weld mark or a flow mark in some cases. On the other hand, when the MFR exceeds 30, there is apprehension that the mechanical and physical properties of a molded article descend. Particularly, when a high-density polyethylene is used, the MFR is preferably 0.005 to 10. When a low-density polyethylene, polypropylene or polybutene is used, the MFR is preferably 0.005 to 20.
[0033] The colorant of the present invention may be a pellet-form colorant called a masterbatch which is composed of a pigment composition and a plastic and contains a pigment at a high concentration. The masterbatch containing a pigment at a high concentration is diluted with a plastic, and then the masterbatch diluted with the plastic is molded to obtain a molded article.
[0034] When the masterbatch is compared with a colored pellet, their processing steps are not largely different from each other. Since the masterbatch contains a pigment at a high concentration, the master batch is slightly more costly than the colored pellet. However, the masterbatch is diluted with a low-price plastic by 0.5 to 200 times for obtaining a molded article. In view of end products, it is cheaper and more preferable to obtain a molded article from the masterbatch by diluting it with a plastic than to obtain a molded article from the coloring pellet.
[0035] The masterbatch preferably contains 100 parts by weight of a plastic and 0.1 to 300 parts by weight of the pigment composition of the present invention. When the amount of the pigment composition is smaller than 0.1 part by weight, there is no meaning as a masterbatch. When the amount of the pigment composition is larger than 300 parts by weight, the pelletization of the masterbatch is difficult. The masterbatch containing a pigment at a high concentration is diluted with a plastic and then molded to obtain a molded article. The plastic used for the dilution is, for example, the same as the plastic used for masterbatch containing a pigment at a high concentration. Further, it is preferable that a molded article as an end product from the masterbatch preferably has a plastic content of 100 parts by weight and a colorant content of 0.001 to 10 parts by weight similarly to a molded article obtained from the before-mentioned colored pellet which does not need to be diluted and is directly molded.
[0036] The masterbatch may contain some other component so long as it hampers the effect of the present invention or causes no sanitary problem. The other component includes a different organic pigment, an inorganic pigment, a different plastic, a low-molecular-weight polyolefine or a derivative thereof, a heavy metal deactivator, a metallic soap of a metal such as an alkali metal, an alkaline earth metal or zinc, hydrotalcite, an antistatic agent such as a nonionic surface active agent, a cationic surface active agent, an anionic surface active agent or an ampholytic surface active agent, a flame retardant such as a halogen type flame retardant, a phosphorus type flame retardant or a metal oxide, a lubricant such as ethylenebis alkylamide, an antioxidant, an ultraviolet absorber, a processing aid, a filler, and a variety of known additives for a polymer.
[0037] In the production of the colorant of the present invention, it is preferred to preprocess the pigment composition of the present invention by treating it with a dispersing agent such as a polyethylene wax before mixing the pigment composition with plastic. As a method for the preprocessing, there are a method in which the pigment composition and the dispersing agent are simply mixed with a mixer and a method in which the pigment composition and the dispersing agent are melt-kneaded and then milled. For obtaining a masterbatch in which the pigment composition is uniformly dispersed, the latter processing method comprising melt-kneading is preferable.
[0038] In the present invention, the molding method of molding and processing a plastic for obtaining a molded article is not specially limited. The molding method includes injection molding, blow molding, inflation molding, extrusion molding, Engel molding, vacuum molding, etc. The effect of preventing the warpage or deformation of a colored molded article can be obtained regardless of molding methods.
EXAMPLES
[0039] The present invention will be explained more in detail with reference to Examples hereinafter, while the present invention shall not be specially limited to these Examples. In the Examples, “part” and “%” stand for “part by weight” and “%” by weight” respectively, unless otherwise specified. Further, the number of halogen substituents of halogenated phthalocyanine obtained in each of Production Examples was measured by a mass spectrum (JMS-DX303HF supplied by JEOL DATUM LTD.).
[0040] Evaluation for warpage or deformation was carried out as follows. A plate was molded with an injection-molding machine using a mold for contractility evaluation (mold provided with marked lines of 10.00 cm in the direction of injection and in the direction perpendicular thereto, for producing a plate having a length of 150 mm, a width of 120 mm and a thickness of 2mm). The molded plate was stored in a thermostatic chamber for 3 days. Then, the degree of warpage or deformation was evaluated by a contraction difference ratio calculated from a ratio between a contraction coefficient in the direction of injection and a contraction coefficient in the direction perpendicular thereto and by visual observation. 20 plates were continuously injection-molded at a molding temperature of 220° C. and at a mold temperature of 40° C., and 6 plates of the 20 plates, from the 14th plate to the 19th plate, were used for the evaluation. The molded plates were stored in a thermostatic chamber for 24 hours or more, then, distances from the marked lines were measured with an accurate caliper, and the contraction coefficient in the direction of injection and the contraction coefficient in the direction perpendicular thereto were obtained from the measured values. Then, the degree of warpage or deformation was evaluated by a contraction difference ratio calculated from a ratio between the contraction coefficient in the direction of injection and the contraction coefficient in the direction perpendicular thereto and by visual observation. The calculating equation for the contraction difference ratio is represented by the equation (1). Generally, when the difference between the contraction difference ratio of a molded plate composed of a pigment and a resin and the contraction difference ratio of a molded plate composed of the resin alone (to be referred to as “natural” hereinafter) is 10% or less, it is called a low contraction pigment or a low contraction pigment composition.
Contraction difference ratio=(contraction coefficient in injection direction−contraction coefficient in perpendicular direction)/contraction coefficient in injection direction Equation (1):
[0041] A standard for the visual observation was as follows. The molded plate was compared with a colorless molded plate (to be referred to as “natural plate” hereinafter) made of a plastic alone, when the degree of warpage or deformation of the molded plate was almost the same as that of the natural plate, it was considered to be free from an influence of a pigment and evaluated as “Good”. When the degree of warpage or deformation of the molded plate was intense, it was evaluated as “Poor”.
[0042] The measurement of a hue was carried out as follows. 1 part of one of pigment compositions used in Examples, 1 part of zinc stearate, 1,000 parts of polypropylene and 50 parts of titanium oxide were sufficiently mixed, the mixture was kneaded with a single-screw extruder to obtain a compound, and the compound was molded with an injection-molding machine, to obtain a molded plate having a thickness of 2 mm. The molded plate was measured for a reflectance with a color-difference meter “KURABO Color-7E” (supplied by KURABO Industries LTD.) to carry out a color measurement in the L*a*b: hue system. Comparative Example 1 using Lionol Blue FG-7351 (C.I. Pigment Blue 15:3, supplied by Toyo Ink Mfg. Co., Ltd.) as a pigment composition was used as a control for the hue difference measurement. A color difference from the control was obtained. When ΔE was in the range of 3.0 or lower and Δb was in the range of 2.0 or lower, the hue was evaluated as “Good”. When ΔE and Δb were not in the above ranges, the hue was evaluated as “Poor”.
[0043] A color development intensity was measured as follows. 1 part of a pigment composition, 1 part of zinc stearate, 1,000 parts of polypropylene and 50 parts of titanium oxide were sufficiently mixed, the mixture was kneaded with a single-screw extruder to obtain a compound, and the compound was molded with an injection-molding machine, to obtain a molded plate having a thickness of 2 mm. The molded plate was measured for a reflectance with a color-difference meter “KURABOColor-7E” (supplied by KURABO Industries LTD.), to measure a reflection intensity at 640 nm. The Kubelka-Munk function (k/s) (color development intensity) of the molded plate was obtained from the above reflection intensity. The number of the color development intensity was rounded off in the first decimal place.
[0044] Examples of synthesis of a halogenated phthalocyanine are shown in Production Examples 1 to 4.
Production Example 1
[0045] 200 parts of aluminum chloride and 40 parts of a common salt were heated to obtain molten salts. 40 parts of a crude copper phthalocyanine was added to the molten salts, the mixture was heated up to 180° C., and chlorine in an amount of 2 parts per hour was introduced for 3 hours. The total amount of the chlorine introduced was 8 parts. After the introduction of the chlorine, the reaction mixture was poured into a large amount of water, followed by filtration and washing with water, drying, and milling, to obtain 46 parts of a chlorinated copper phthalocyanine. The chlorinated copper phthalocyanine was added to 300 parts of 98% sulfuric acid, and the mixture was stirred at 40-45° C. for 4 hours. Then, the mixture was added to 2,000 parts of water. The resultant mixture was stirred at 80° C. for 2 hours, followed by filtration, washing with water, drying, and milling, to obtain 45 parts of a chlorinated copper phthalocyanine. The number of halogen substituents of the chlorinated copper phthalocyanine was 1 to 6, and the average number of the substituents was 3.2.
Production Example 2
[0046] 200 parts of aluminum chloride and 40 parts of a common salt were heated to obtain molten salts. 40 parts of a crude copper phthalocyanine was added to the molten salts, the mixture was heated up to 180° C., and bromine in an amount of 3 parts per hour was dropwise added for 5 hours. The total amount of the bromine added was 18 parts. After the addition of the bromine, the reaction mixture was poured into a large amount of water, followed by filtration and washing with water, drying, and milling, to obtain 55 parts of a brominated copper phthalocyanine. The brominated copper phthalocyanine was added to 300 parts of 98% sulfuric acid, and the mixture was stirred at 40-45° C. for 4 hours. Then, the mixture was added to 2,000 parts of water. The resultant mixture was stirred at 80° C. for 2 hours, followed by filtration, washing with water, drying, and milling, to obtain 52 parts of a brominated copper phthalocyanine. The number of halogen substituents of the brominated copper phthalocyanine was 1 to 5, and the average number of the substituents was 2.8.
Production Example 3
[0047] 200 parts of aluminum chloride and 40 parts of a common salt were heated to obtain molten salts. 40 parts of a crude copper phthalocyanine was added to the molten salts, the mixture was heated up to 180° C., and chlorine in an amount of 2 parts per hour was introduced for 10 hours. The total amount of the chlorine introduced was 22 parts. After the introduction of the chlorine, the reaction mixture was poured into a large amount of water, followed by filtration and washing with water, drying, and milling, to obtain 58 parts of a chlorinated copper phthalocyanine. The chlorinated copper phthalocyanine was added to 300 parts of 98% sulfuric acid, and the mixture was stirred at 40-45° C. for 4 hours. Then, the mixture was added to 2,000 parts of water. The resultant mixture was stirred at 80° C. for 2 hours, followed by filtration, washing with water, drying, and milling, to obtain 57 parts of a chlorinated copper phthalocyanine. The number of halogen substituents of the chlorinated copper phthalocyanine was 5 to 11, and the average number of the substituents was 8.0.
Production Example 4
[0048] 200 parts of aluminum chloride and 40 parts of a common salt were heated to obtain molten salts. 40 parts of a crude copper phthalocyanine was added to the molten salts, the mixture was heated up to 180° C., and bromine in an amount of 6 parts per hour was dropwise added for 6 hours. The total amount of the bromine added was 42 parts. After the addition of the bromine, chlorine in an amount of 2 parts per hour was introduced for 9 hours. The total amount of the chlorine introduced was 20 parts. After the introduction of the chlorine, the reaction mixture was poured into a large amount of water, followed by filtration and washing with water, drying, and milling, to obtain 92 parts of a brominated and chlorinated copper phthalocyanine. The brominated and chlorinated copper phthalocyanine was added to 600 parts of 98% sulfuric acid, and the mixture was stirred at 40-45° C. for 4 hours. Then, the mixture was added to 4,000 parts of water. The resultant mixture was stirred at 80° C. for 2 hours, followed by filtration, washing with water, drying, and milling, to obtain 90 parts of a brominated and chlorinated copper phthalocyanine. The number of halogen substituents of the brominated and chlorinated copper phthalocyanine was 12 to 16, and the average number of the substituents was 14.5.
Example 1
[0049] 88 parts of a phthalocyanine pigment (C.I. Pigment Blue 15:3, trade name Lionol Blue FG-7351, supplied by Toyo Ink Mfg. Co., Ltd.), 10 parts of a halogenated phthalocyanine produced according to the Production Example 1, and 2 parts of a phthalocyanine derivative represented by Compound A were mixed with a mixer, to obtain a pigment composition. Then, 100 parts of the pigment composition and 100 parts of calcium stearate were mixed with a mixer to obtain a colorant. 2 parts of the colorant, 1,000 parts of a high-density polyethylene resin (trade name Hizex 2100J supplied by Sumitomo Mitsui Polyolefin) and a few drops of an adhesion agent were sufficiently mixed by tumbling. Then, the mixture was molded into a plate with an injection molding machine, and the plate was evaluated for warpage or deformation and a hue. In comparison with a natural plate, the above molded plate showed a contraction difference ratio close to that of the natural plate, and the degree of warpage or deformation by visual observation was almost the same as that of the natural plate. Further, the hue was good similarly to a plate colored with the phthalocyanine pigment alone. The above molded plate was a high tinting strength plate.
Comparative Example 1
[0050] A molded plate was prepared in the same manner as in Example 1 except that the halogenated phthalocyanine and the phthalocyanine derivative used in Example 1 were not used. In comparison with a natural plate, the contraction difference ratio of the molded plate was large, and the degree of warpage or deformation was also large by visual observation.
Comparative Example 2
[0051] A molded plate was prepared in the same manner as in Example 1 except that the phthalocyanine derivative used in Example 1 was not used. In comparison with a natural plate or the plate of Example 1, the contraction difference ratio was large, and the degree of warpage or deformation was also large by visual observation.
Comparative Example 3
[0052] A molded plate was prepared in the same manner as in Example 1 except that the halogenated phthalocyanine used in Example 1 was not used. In comparison with a natural plate or the plate of Example 1, the contraction difference ratio was large, and the degree of warpage or deformation was also large by visual observation.
Comparative Example 4
[0053] A molded plate was prepared in the same manner as in Example 1 except that the halogenated phthalocyanine used in Example 1 was not used and that the amount of the phthalocyanine derivative was changed to 20 parts. The contraction difference ratio thereof was small and no warpage was found by visual observation. However, the hue thereof was poor, and the color development was poor or 95% based on the control.
Comparative Example 5
[0054] A molded plate was prepared in the same manner as in Example 1 except that the pigment composition used in Example 1 was replaced with 100 parts of a halogenated phthalocyanine produced according to the Production Example 1. In comparison with a natural plate, the above molded plate showed a contraction difference ratio close to that of the natural plate, and the degree of warpage or deformation by visual observation was almost the same as that of the natural plate. However, the hue was poor, and the color development was poor or 90% based on the control.
Example 2
[0055] A molded plate was prepared in the same manner as in Example 1 except that the high-density polyethylene resin (trade name Hizex 2100J supplied by Sumitomo Mitsui Polyolefin) used in Example 1 was replaced with a polypropylene resin (trade name Mitsui Sumitomo PP, supplied by Sumitomo Mitsui Polyolefin) In comparison with a natural plate, the above molded plate showed a contraction difference ratio close to that of the natural plate, and the degree of warpage or deformation by visual observation was almost the same as that of the natural plate. Further, the hue was good and the tinting strength was equivalent to that of the control.
Comparative Example 6
[0056] A molded plate was prepared in the same manner as in Example 2 except that the halogenated phthalocyanine and the phthalocyanine derivative used in Example 2 were not used. In comparison with a natural plate, the contraction difference ratio was large, and the degree of warpage or deformation was also large by visual observation.
Comparative Example 7
[0057] A molded plate was prepared in the same manner as in Example 2 except that the phthalocyanine pigment used in Example 2 was not used. In comparison with a natural plate or the plate of Example 1, the contraction difference ratio was large, and the degree of warpage or deformation was also large by visual observation.
Comparative Example 8
[0058] A molded plate was prepared in the same manner as in Example 2 except that the halogenated phthalocyanine used in Example 2 was not used. In comparison with a natural plate or the plate of Example 1, the contraction difference ratio was large, and the degree of warpage or deformation was also large by visual observation.
Example 3
[0059] A molded plate was prepared in the same manner as in Example 1 except that the halogenated phthalocyanine used in Example 1 was replaced with a halogenated phthalocyanine produced according to the Production Example 2. In comparison with a natural plate, the above molded plate showed a contraction difference ratio close to that of the natural plate, and the degree of warpage or deformation by visual-observation was almost the same as that of the natural plate. Further, the hue was good and the tinting strength was equivalent to that of the control.
Comparative Examples 9-10
[0060] Molded plates were obtained in the same manner as in Example 3 except that the halogenated phthalocyanine used in Example 3 was replaced with a halogenated phthalocyanine produced according to the Production Example 3 in Comparative Example 9, and that the halogenated phthalocyanine was replaced with a halogenated phthalocyanine produced according to the Production Example 4 in Comparative Example 10. Each of the molded plates had a large contraction difference ratio and the degree of warpage or deformation of each molded plate was also large by visual observation. Further, the hue of each molded plate was poor.
Examples 4-11
[0061] Molded plates were prepared in the same manner as in Example 1 except that the phthalocyanine derivative used in Example 1 was replaced with phthalocyanine derivatives of the following chemical formulae respectively. In comparison with a natural plate, each of the obtained molded plates showed a contraction difference ratio close to that of the natural plate, and the degree of warpage or deformation of each molded plate by visual observation was almost the same as that of the natural plate. Further, the hue was good and the tinting strength was equivalent to that of the control.
Example 12
[0062] 88 parts of a phthalocyanine pigment (C.I. Pigment Blue 15:3, trade name Lionol Blue FG-7351, supplied by Toyo Ink Mfg. Co., Ltd.), 10 parts of a halogenated phthalocyanine produced according to the Production Example 1, and 2 parts of a phthalocyanine derivative represented by Compound A were mixed with a mixer, to obtain a pigment composition. 100 parts of the pigment composition and a polyethylene wax (trade name: High Wax NL-500, supplied by Mitsui Chemicals, Inc.) were sufficiently mixed, then the mixture was melt-kneaded with a three-roll, and then the kneaded mixture was milled to obtain a processing pigment. 4 parts of the processing pigment and 100 parts of a high-density polyethylene were mixed and then the mixture was melt-kneaded with a twin-screw extruder, to obtain a pellet-form masterbatch. Then, 5 parts of the masterbatch and 100 parts of a high-density polyethylene resin (trade name Hizex 2100J supplied by Sumitomo Mitsui Polyolefin) were mixed and then the mixture was injection-molded with an injection molding machine into a plate similarly to Example 1. The molded plate was similarly evaluated. In comparison with a natural plate or the plate of Example 1, the above molded plate showed a contraction difference ratio close to that of the natural plate or the plate of Example 1, and the degree of warpage or deformation by visual observation was almost the same as that of the natural plate or the plate of Example 1.
Example 13
[0063] A molded plate was obtained in the same manner as in Example 1 except that the pigment used in Example 1 was replaced with a phthalocyanine pigment (C.I. Pigment Blue 15:1, trade name Lionol Blue 7110-V, supplied by Toyo Ink Mfg. Co., Ltd.). In comparison with a natural plate, the above molded plate showed a contraction difference ratio close to that of the natural plate, and the degree of warpage or deformation by visual observation was-almost the same as that of the natural plate. Further, the hue was good similarly to a plate colored with the phthalocyanine pigment alone. The above plate was a high tinting strength plate.
Example 14
[0064] 88 parts of a phthalocyanine pigment (C.I. Pigment Blue 15:3, trade name Lionol Blue FG-7351, supplied by Toyo Ink Mfg. Co., Ltd.), 10 parts of a halogenated phthalocyanine produced according to the Production Example 1, and 2 parts of a phthalocyanine derivative represented by Compound A were mixed with a mixer, to obtain a pigment composition. 1 part of the above pigment composition, 1 part of magnesium stearate and 1,000 parts of a polyethylene terephthalate resin (trade name Vylopet EMC-307, Toyobo Co., Ltd.) were mixed, the mixture was kneaded with an injection-molding machine at a molding temperature of 275° C. and at a mold temperature of 85° C., to obtain a molded plate. In comparison with a natural plate, the above molded plate showed a contraction difference ratio close to that of the natural plate, and the degree of warpage or deformation by visual observation was almost the same as that of the natural plate. Further, the hue was good similarly to a plate colored with the phthalocyanine pigment alone. The above molded plate was a high tinting strength plate.
Comparative Example 11
[0065] A molded plate was obtained in the same manner as in Example 9 except that the halogenated phthalocyanine and the phthalocyanine derivative used in Example 9 were not used. In comparison with a natural plate, the contraction difference ratio of the molded plate was large, and the degree of warpage or deformation was also large by visual observation.
[0066] Table 1 shows results of Examples 1-14 and Comparative Example 1-11.
TABLE 1 Kind of Halogenated Phthalocyanine Pigment phthalocyanine derivative C.I. Pigment Production Content Content Resin Index Example (% by weight) Compound (% by weight) Resin Ex. 1 Pigment Blue Production 10 Compound A 2 HDPE 15:3 Example 1 CEx. 1 Pigment Blue HDPE 15:3 CEx. 2 Pigment Production 10 HDPE Blue 15:3 Example 1 CEx. 3 Pigment Blue Compound A 2 HDPE 15:3 CEx. 4 Pigment Blue Compound A 20 HDPE 15:3 CEx. 5 Production 100 HDPE Example 1 Ex. 2 Pigment Blue Production 10 Compound A 2 PP 15:3 Example 1 CEx. 6 Pigment Blue PP 15:3 CEx. 7 Pigment Blue Production 10 PP 15:3 Example 1 CEx. 8 Pigment Blue PP 15:3 Ex. 3 Pigment Blue Production 10 Compound A 2 HDPE 15:3 Example 2 CEx. 9 Pigment Blue Production 10 HDPE 15:3 Example 3 CEx. 10 Pigment Blue Production 10 HDPE 15:3 Example 4 Ex. 4 Pigment Blue Production 10 Compound B 2 HDPE 15:3 Example 1 Ex. 5 Pigment Blue Production 10 Compound C 2 HDPE 15:3 Example 1 Ex. 6 Pigment Blue Production 10 Compound D 2 HDPE 15:3 Example 1 Ex. 7 Pigment Blue Production 10 Compound E 2 HDPE 15:3 Example 1 Ex. 8 Pigment Blue Production 10 Compound F 2 HDPE 15:3 Example 1 Ex. 9 Pigment Blue Production 10 Compound G 2 HDPE 15:3 Example 1 Ex. 10 Pigment Blue Production 10 Compound H 2 HDPE 15:3 Example 1 Ex. 11 Pigment Blue Production 10 Compound I 2 HDPE 15:3 Example 1 Ex. 12 Pigment Blue Production 10 Compound A 2 HDPE 15:3 Example 1 Ex. 13 Pigment Blue Production 10 Compound A 2 HDPE 15:1 Example 1 Ex. 14 Pigment Blue Production 10 Compound A 2 PET 15:3 Example 1 CEx. 11 Pigment Blue PET 15:3 Measurement results of Plate Contraction Warpage difference (Visual Color ratio observation) Hue development Ex. 1 3.4 Good Good 100 CEx. 1 45.7 Poor Good 100 CEx. 2 22.0 Poor Good 100 CEx. 3 31.0 Poor Good 100 CEx. 4 9.2 Good Poor 95 CEx. 5 7.7 Good Poor 90 Ex. 2 −8.8 Good Good 100 CEx. 6 −23.0 Poor Good 100 CEx. 7 −19.0 Poor Good 100 CEx. 8 −15.0 Poor Good 100 Ex. 3 3.6 Good Good 100 CEx. 9 45.1 Poor Poor 92 CEx. 10 43.7 Poor Poor 94 Ex. 4 3.7 Good Good 100 Ex. 5 5.2 Good Good 100 Ex. 6 8.9 Good Good 100 Ex. 7 7.7 Good Good 100 Ex. 8 5.3 Good Good 100 Ex. 9 5.9 Good Good 100 Ex. 10 8.6 Good Good 100 Ex. 11 6.2 Good Good 100 Ex. 12 6.8 Good Good 100 Ex. 13 9.1 Good Good 100 Ex. 14 9.8 Good Good 100 CEx. 11 22.4 Poor Good 100 Ex. = Example, CEx. = Comparative Example
Effect of the Invention
[0068] According to the present invention, the warpage, deformation or dimensional change of a molded article can be decreased while retaining excellent properties of clear hue and color development of phthalocyanine. The number of defective 10 articles due to warpage or deformation of a molded article decreases, so that an improvement in productivity is achieved. | A pigment composition composed of 50 to 95% by weight of a phthalocyanine, 1 to 45% by weight of a halogenated phthalocyanine of which the number of substituents of a halogen atom is 1 to 9 and the average number of the substituents is 2.0 to 4.0 and 0.1 to 10% by weight of a phthalocyanine derivative of the formula (1) or a phthalimide methylated phthalocyanine derivative, a colorant containing the above pigment composition and a molded article obtained from a plastic containing the above colorant,
P-(X)m (1)
wherein P represents a phthalocyanine structure, X represents an alkyl group having 12 to 18 carbon atoms, an alkoxy group having 12 to 18 carbon atoms, —SO 2 NHR, —SO 2 NR 2 , —NR 2 , —CONR 2 , —CONHR or —SR (wherein R represents an alkyl group or an alkenyl group which has 12 to 18 carbon atoms), and m is an integer of 1 to 4. | 2 |
BACKGROUND OF THE INVENTION
This invention relates generally to method and apparatus for forming seals between a housing and a shaft having relative rotation therebetween. More particularly, but not by way of limitation, this invention relates to a method for forming a seal between the housing and a shaft and to a seal that is of the labyrinth type.
Labyrinth seals have been known and have been in use for many years. U.S. Pat. No. 1,626,237 issued Apr. 26, 1927 to Francis Hodgkinson illustrates one type of labyrinth seal. In the seal of that patent, the lands of the seal are spaced in progressively different widths to create a throttling effect across the seal and to drop the differential progressively in each of the chambers between seal lands. The spacer members between the lands of this seal are constructed from a relatively soft material so that they can be distorted by tightening, bringing more of the land members into sealing engagement to assure that a fluid-tight seal is maintained. In this seal, rubbing contact is utilized.
Another type of labyrinth seal is illustrated in U.S. Pat. No. 4,290,610 to Lizogub et al. on Sept. 22, 1981. This seal is somewhat similar to the seal illustrated in the '237 patent, but apparently no rubbing occurs between the lands of the seal.
It is also previously known to distribute pressure across the seal to reduce the differential across any sealing element to the desired quantity. Such arrangements are illustrated in the U.S. Pat. No. 1,996,780 issued Apr. 9, 1935 to H. T. Wheeler, and in U.S. Pat. No. 3,071,384 issued Jan. 1, 1963 to J. M. E. Friberg. Although these patents are not of the labyrinth seal type, they do illustrate the utilization of various pressures across the total seal to reduce the differential across any single sealing element.
Labyrinth seals have been successfully used over the years. However, as the housing and shaft, each of which contains part of the seal, are generally constructed from different materials, temperature changes in the machine will cause a different amount of thermal expansion or contraction in the shaft and in the housing. Accordingly, the spacing of the seals, which was done during assembly, may not remain correct. Consequently, extra rubbing between the seal parts or large spaces may occur in the seal which may cause leakage or destruction of the seal.
SUMMARY OF THE INVENTION
An object of this invention is to provide an improved seal system for use between a shaft and housing wherein the sealing element automatically adapts itself to dimensional changes of the shaft and the housing.
Another object of this invention is to provide a method for constructing a seal for use between the housing and the shaft that will automatically compensate for changes in dimensions between the housing and the shaft.
This invention then provides a shaft sealing system for use in apparatus that includes a shaft and a housing, through which the shaft extends and wherein relative rotation occurs between the shaft and the housing.
The system comprises first and second annular land members that are located on the shaft and project toward the housing; an annular spacer member that is positioned on the shaft between the land members; and a generally annular seal member that frictionally engages the housing and is located between and in close proximity to the land members. The movement of the land members, due to axial changes in the shaft, reposition the seal member in the housing to maintain an effective seal between the shaft and the housing.
In another aspect, this invention provides a method for forming a shaft sealing system in apparatus including a housing having a bore therethrough and including a shaft that is relatively rotatable in the bore. The method comprises the steps of pressing the first annular land member on the shaft, positioning an annular spacer member on the shaft abutting the first land member; locating a generally annular seal member in encircling relationship to the spacer member and adjacent to the land member; pressing a second annular land member on the shaft abutting the spacer member; and temporarily reducing the diameter of the seal member while inserting the shaft, land member, spacer member and seal member into the bore until the seal member is located in the desired position.
BRIEF DESCRIPTION OF THE DRAWING
The foregoing and additional objects and advantages of the invention will become more apparent as the following detailed description is read in conjunction with the accompanying drawing, wherein like reference characters denote like parts in all views and wherein:
FIG. 1 is a cross-sectional view, partly schematic, illustrating a seal system constructed in accordance with the invention;
FIG. 2 is an enlarged, partial elevation view illustrating the end portions of one of the sealing rings illustrated in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing and to FIG. 1 in particular, shown therein and generally designated by the reference character 10 is a sealing system that is constructed in accordance with the invention. The sealing system 10 is installed in a machine, such as a centrifugal blower or compressor (not shown) that includes a housing 12 having a bore 14 extending therethrough for receiving a shaft 16. The shaft 16 is rotatably supported in the housing 12 by appropriate bearings (not shown). The housing 12, in addition to the bore 14, includes passageways 18 and 20 for purposes that will be described hereinafter.
The sealing system 10 includes control means 22 and 24 that are operably disposed in the passageways 18 and 20, respectively. Each of the control means 22 and 24 may be a device such as a throttling valve, orifice or other more elaborate control that serves the function of controlling the pressure of fluid that is in the passageways 18 and 20. The control means 22 and 24 may be either located within the housing 12 or maybe external thereof, as desired.
The sealing system 10 also includes a plurality of spaced, annular land members 26, 28, 30, 32, 34 and 36. The land members are pressed on the shaft 16 and are held on the shaft in spaced relationship by annular spacer members 38, 40, 42, 44, and 46. In the type of device wherein the shaft 16 is rotating relative to the housing 12, the land members and spacer members rotate with the shaft 16.
The sealing system 10 also includes a plurality of spaced annular seal members 48, 50 and 52 which are not quite as wide as the spacer members to avoid rubbing between the seal and land members. Each of the spacer members and each of the seal members encircle the shaft 16. The seal members 48, 50 and 52 are retained in their respective positions as illustrated in FIG. 1 by frictional engagement of the seal members with the housing 12 in the bore 14.
The enlarged illustration of FIG. 2, shows end portions 54 and 56 of the seal member 48, which is typical, in greater detail. As shown therein, the end portions 54 and 56 lie in juxtaposition and are slightly spaced apart so that the seal members 48, 50 and 52 can be collapsed for assembly as will be described in more detail.
It will be noted in FIG. 1 that the passageway 18 is disposed so that it communicates with the bore 14 adjacent to a cavity 58 formed between the land members 28 and 30 and adjacent to the spacer member 40. Similarly, the passageway 20 intersects the bore 14 at cavity 60 which is located between the land members 32 and 34 and adjacent to the spacer member 44.
The seal system 10 is assembled on the shaft 16 and in the housing 12 in the following manner: the land member 26 is pressed on the shaft 16 followed by spacer member 38, seal member 48 and land member 28 which is pressed on the shaft 16 until it abuts the spacer member 48. As previously mentioned, the spacer member 38 is slightly wider than the width of the seal member 48, so that the seal member 48 is not in engagement with either of the land members 26 or 28, except inadvertently. As will be apparent, the land members 26 and 28, spacer member 38 and the seal member 58 form one complete sealing unit which could function in the machine if a relatively low differential pressure exists thereacross. The precise number of these "units" needed will depend on the differential to be controlled across the seal system 10. In the illustrated system of FIG. 1, it is assumed that the pressure differential across the entire sealing system 10 will be approximately 120 to 125 psi, thus the pressure drop across any one of the "units" will be about 40 psi. To assure that this is so, the control device 22 is set so that the pressure in the passageway 18 and the pressure in the cavity 58 is about 80 psi.
Returning to the assembly of the sealing system 10, the spacer 40 is placed on the shaft 16 followed by pressed on land member 32, spacer member 42 and seal member 50. Land member 32 is pressed on until it abuts the spacer member 42. It can be seen that the differential in pressure across the seal assembly 10, that is, across two "units" could be divided over the seal members 48 and 50 by regulating the pressure in the passageway 18 to approximately 60 psi and thus, assuring that the drop across each of the seal rings is reduced to approximately 60 psi. However, it is believed that stiffness of the seal members may become a problem if they are constructed to withstand over about 50 psi differential.
The foregoing described assembly procedure is repeated placing the spacer member 44 on the shaft 16, followed by the land member 34 which is pressed thereon, spacer member 46 and seal member 52 with the last land member 36 being pressed on the shaft 16 and into engagement with the spacer member 46. As now assembled, assuming that the pressure across the sealing system 10 will be 120 psi, pressure in the passageway 18 is controlled to about 80 psi assuring a 40 psi drop across the seal member 48. Pressure in the passageway 20 is controlled at about 40 psi, assuring that the pressure drop across the seal member 50 is 40 psi, and since the pressure in the bore outside the land member 36 is 0 psig, the pressure across the seal member 52 is also 40 psi.
To place the shaft 16 with the assembled sealing elements, land members and spacer members thereon into the bore 14, the seal member 52 is temporarily held with its diameter reduced to an amount less than the diameter of the bore 14. The shaft 16 is then inserted into the bore 14 to the point that the seal member 52 is contained within the bore. The seal member 50 is then temporarily reduced in diameter and placed into the bore 14 and subsequently, the seal member 48 is reduced in diameter and placed in the bore 14. As will be appreciated, the seal members 48, 50 and 52 are retained in the bore 14 by friction, and thus, when the shaft 16 is inserted into the bore 14, the land members which have been pressed on the shaft 16, move the seal members into their desired positions. In assemblies where the space is inadequate to hold the seal members 48, 50 and 52, an entering bevel (not shown) may be provided in the bore 14 so that the diameter is reduced by forcing the shaft 16 and seal members into the bore 14.
In the operation of the sealing system 10, which has been described to some extent hereinbefore, the sealing system 10 is assembled as described, and the shaft 16 is driven by a motor (not shown) causing it to rotate in the bore 14. Heat is generated during the compressing operation, thus the shaft 16 tends to elongate. Of course, the housing 12 also changes in dimension, but since the housing 12 and the shaft 16 are generally constructed from different materials, and are of different configuration, the dimensional changes are not of an equal amount. The land members, being pressed on the shaft 16, move with the shaft 16, and thus, are somewhat repositioned by the dimensional changes of the shaft 16. The seal members 48, 50 and 52, being only frictionally retained within the bore 14, move in response to movement of the land members, realigning themselves as necessary to accommodate the dimensional changes in the housing 12 and shaft 16. Thus, a constant efficient seal is assured, even though dimensional changes occur in the machine.
From the foregoing detailed description, it can be seen that the sealing system 10, when constructed in accordance with this invention, provides for the automatic adaptation of the seal to dimensional changes between the shaft and housing whatever may be the cause of such dimensional changes.
Having described but a single embodiment of this invention, it will be apparent that many changes and modifications can be made thereto without departing from the spirit and scope of the invention. | The shaft seal includes at least first and second annular land members that are located on the shaft and toward the housing, an annular spacer member positioned on the shaft between the land members, a generally annular seal member frictionally engaging the housing and located between the land members. The arrangement is such that changes in axial dimension of the shaft will cause repositioning of the seal member and thus maintain an effective seal between the shaft and the housing. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to tenter apparatus hereinafter stenter apparatus for stretching a web to produce a relatively thin film, and especially to stenter apparatus comprising laterally spaced pairs of endless chains or bands each of which includes film clip holders running on rails, facing inner or feed runs of the chains or bands defining a film conveying passage comprising in succession an inlet section, a diverging film stretching section and an outlet or relaxation section, end sprockets being present at the ends of the inner feed run and the outer or return run of the chains. Such apparatus is hereinafter referred to as stenter apparatus of the type aforesaid.
Stenter apparatus of the type aforesaid in shown in UK Patent Specification No. 1015499 wherein the film holder rails are mounted on a supporting frame structure. For heating and/or cooling of the film, the stenter of No. 1015499 includes chamber means through which passes film gripped on the feed runs of the chains, the chamber means consequently housing the portions of the feed runs of the chains defining at least parts of the film feed, stretching and outlet sections. For operational and economy reasons the return runs of the chains are located outside the chamber means. Additionally No. 1015499 includes adjustment means for lateral movement of the feed and return runs of each chain in parallelogram manner so that the spacing between the opposed feed runs can be varied so as to enable for example the degree of stretch imparted by the apparatus to be varied. More specifically the rails comprise a series of pivotally jointed sections with a carrying block at each joint, and the adjustment means includes transverse control shafts threaded to said carrying blocks and rotatable to move the blocks for parallelogram motion f the feed and return rail sections of each endless chain, the adjustment means being such that opposed lateral movements of the two chains are effected simultaneously relative to the centre-line of the stenter. Equivalent lateral movements are imparted to the end sprockets. The necessary apertures at the ends of the chamber means for the feed runs are of sealed slot form to accommodate the lateral movements of the feed runs. The stenter apparatus of No. 1015499 has the following disadvantages, namely:
1. The stenter apparatus is complex, in particular requiring a considerable number of pivotal joints for the rail sections to permit desired width variations and patterns to be obtained along the length of the film conveying passage; and
2. The end sprockets have to be of relatively large diameter to allow a reasonable degree of lateral movement of the inner feed run if the outer return run which moves laterally with the feed run is not to foul the chamber means.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved stenter apparatus of the type aforesaid which obviates or mitigates these disadvantages.
According to the present invention, stenter apparatus of the type aforesaid includes shifting means to permit adjustment movements of the feed run towards or away from the corresponding return run, and pivot means to permit pivoting motion of portions of the return run adjacent the ends of the run to allow said adjustment movements.
Thus by the present invention the bulk of the return run of each chain or band can occupy a set position while the feed runs are movable laterally as desired relative to the set return runs for variation of the width pattern of the film conveying passage. Again the end sprockets move laterally in unison with the associated feed run. The set outer run can therefore utilise a continuous rail or fixed rail section and there is a consequent reduction in the number of pivot joints required, all of which leads to economies in the construction. Further, since the outer run does not now move laterally with the feed run end sprockets of considerably reduced diameter can be utilised.
Preferably the pivot means comprises an adjustable length radius arm.
In a preferred embodiment, the radius arm is hingeably connected at one end to a carrying body of an end sprocket and at the other end to an end of a set section of the return run.
Chain tensioning and adjustment means will desirably be present to cater for the relative changing geometry of the feed and return runs, and these means can be located at an end sprocket.
Preferably the shifting means comprises transversely located rotatable shafts which are threaded to support elements of the inner run; these support elements will be located at pivot points of adjacent sections of the inner run.
In one preferred embodiment both the inner feed run and the outer return run of each endless chain passes through film treatment apparatus e.g. a heater or cooler.
In an alternative embodiment the outer return of the endless chain passes on the outside of film treatment apparatus.
BRIEF DESCRIPTION OF THE INVENTION
Embodiments of the present invention will now be described by way of example with reference to the accompanying drawings wherein,
FIG. 1 shows a schematic plan view of the left hand rail/chain of stenter apparatus to one side of the stentor line, in accordance with one embodiment of the present invention;
FIG. 2 shows in greater detail a plan view of an entry rail portion of the apparatus of FIG. 1;
FIG. 3 shows a plan view of a sprocket support of the entry rail portion;
FIG. 4 shows the section 4--4 of FIG. 3;
FIG. 5 shows in greater detail a plan view of an exit rail portion of the apparatus of FIG. 1;
FIG. 6 shows a side elevation f the mounting arrangement for a sprocket wheel of the rail;
FIG. 7 shows a front elevation of a pivot joint suitable of the apparatus of FIG. 1;
FIG. 8 shows a plan view of a connecting piece pair use in the pivot joint of FIG. 7;
FIG. 9A shows a plan view of a horizontal track including an extension joint of the apparatus of FIG. 1;
FIG. 9B shows a side view of a vertical track including an extension joint;
FIG. 9C shows an end view of the track of FIG. 12B through section K--K in FIG. 9B.
FIG. 10 shows a plan view of a prior art stenter rail/chain including a chain sprocket; and
FIGS. 11 and 12 show views similar to FIG. 1 of second and third embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, stenter apparatus for stretching a web of material so as to produce a thin film comprises a pair of laterally spaced rail systems, one the mirror image of the other, and one of these rail systems 1 (i.e. the stenter's left hand rail) is schematically illustrated in FIG. 1. The rail systems 1 are laterally spaced from the stenter's centre line C--C, and the rail 2A, 2B of the system 1 supports a conveying system including and endless chain with a feed run 9 (i.e. the film rail) and a return run 10, between end sprockets 11B, 12B carried by sprocket carrier members 11, 12. One of the sprockets 12B can serve as a drive sprocket for the chain formed by the holders 3.
The opposed feed runs 9 of the facing rail systems 1 define a film feed conveying passage comprising in succession an inlet section 13 at the inlet end 11A, a diverging film stretching section 14 and finally an outlet (or relaxation) section 15 extending to the outlet end 12A. Suitable apparatus such as that described in UK Patent Specification No. 1598020, can be provided to feed the film web to the inlet section 13.
The web passes through a heating chamber (or oven) 16 extending between the inlet and stretching sections 13, 14 as shown, while crystalling or cooling chambers 17 extend at the outlet section 15. In the FIG. 1 embodiment both the feed and return runs 9, 10 pass through these chambers 16, 17.
It is a requirement that the width pattern of the film conveying passage is variable, for example for variation of the degree of stretch imparted to the film by the stenter or to handle film webs of different width, and for this requirement the present stenter has means for lateral movement of the rail of the feed run 9. In particular, means are provided at various positions of inlet and outlet crossheads X I , X O and intermediate crossheads, X 1 , X 2 , X 3 , . . . X N (depending on number) for transverse motion of the rail at the crossheads as described later. However in accordance with the present invention the bulk of the outer run 10, specifically from point 20A to point 20B, is set in position and is not laterally movable. The rail portion from 20A to 20B can therefore have fixed and continuous tracks without flexible joints, and this provides advantages as regards cost, operation and maintenance. To permit lateral movement of the run 9 relative to the set run 10, end portion 10A, 10B of the run 10 adjacent the end sprockets 11B, 12B are arranged to be pivotal. In this example the portion 10A is pivotal at the second intermediate crosshead X 2 , while the portion 10B is pivotal at the penultimate of the intermediate crossheads. Since the feed entry will always be parallel the inlet sprocket carrier member 11 includes a short fixed arm 11C extending longitudinally to the first flexible joint 19 of the run 9 at the first intermediate crosshead X 1 , while the portion 10A is in the form of a swinging radius arm having one end pivotally connected at point 20A and the other flexibly connected to the sprocket carrier 11 at point 19A. A further arm 11D extends from arm 11C to a pivoting point 19 in run 9 at the second intermediate crosshead X 2 . The arm 10A includes extension means for length adjustability. The arrangement at the outlet end is similar, the swinging arm portion 10B being pivoted at points 20B and 19B on the carrier 12B including longitudinal arms 12C with pivot for the 12C in run 9.
FIG. 1 shows the feed run 9 at maximum width position (full line) and at minimum width position (dashed line), the pivoting of the arm portions 10A, 10B to permit movement of these positions being evident in FIG. 1. The carriers 11, 12 have linear lateral movement (achieved by shifting means as previous) but this is achievable by virtue of the length adjustability of portions 10A, 10B and resultant chain length variation is catered for by a suitable chain tensioning and adjustment device provided at the inlet sprocket 11A. The run 9 will enter and leave the chambers 16, 17 via sealed slots permitting the lateral movement of the run 9. By way of example, the maximum conveying passage width (full line) achievable at outlet may be about four times greater than the minimum width (dashed line) at the inlet.
FIG. 2 shows in greater detail inlet rail support structure defining portions 10A, 11, 11C, 11D suitable for use in the apparatus of FIG. 1. Thus the sprocket carrier 11 comprises a head casting having integral therewith the arm 11C of the feed run 9 and means for pivotally linking the carrier at point 19A to the arm 10A of the return run. The arm 10A includes extension means 22 to cater for changing geometry when the sprocket carrier 11 is moved laterally, and additionally the arm 11C is provided with extension means 22 to facilitate the provision of chain tensioning means at the carrier 11. The dashed line in FIG. 2 shows the dropped position of the end support structure and in particular shows the parallel motion of the arms 11C, 11D into this dropped position with the pivot at position 20A remaining fixed. FIGS. 3 and 4 show the sprocket in even greater detail. Thus, the head casting comprises a hub 30 in which the sprocket wheel 11B of FIG. 1 is journalled while a bracket 31 defining a bush carried by the head casting facilitates the pivotal connection of the arm 10A to the sprocket carrier 11. A further bored bracket 32 serves for imparting lateral movements to the carrier 11 at the crosshead X I .
FIG. 5 shows in detail a rail support structure for the outlet rail end i.e. including arm 10B suitable for the apparatus of FIG. 1. As will be noted this has considerable similarity to the inlet rail end of FIG. 5 but the range of movement of the sprocket carrier 12 is considerably greater than that of carrier 11. Again, the sprocket carrier 12 (in the form of a head casting) includes an arm 12C integral therewith defining part of the feed run 9.
FIG. 6 shows an arrangement for the crosshead X I . Thus there is provided a support column 33 on which a carrier member 34 is slidably mounted via sliding flange arrangement 33A, 34A whereby the carrier member 34 has sliding motion out of the plane of the paper in FIG. 6 i.e. in the transverse direction T--T in FIG. 1. Movement of the carrier member 34 in the direction T--T is achieved by a threaded rod device 35 engaging a "nut" fixed to the member 34. A slider 36 moving on guides 37 on the carrier member 34 supports a pin 38 which is fitted into the bracket 32 of the carrier 11 whereby the various motions are imparted to the carrier 11. The guides 37 enable the slider 36 to have motion in the longitudinal direction L--L for chain tensioning purposes and control of motion of the slider 36 in this direction is through a hydraulic cylinder 39 carried by the member 34 and having an actuating rod 40 coupled to the slider 36. The arrangement at the crosshead X 0 can be similar but in this case provision for motion in the L--L direction will not be required and the cylinder 39 can be dispensed with.
Referring to FIG. 7, the chain comprises holders 3 pivotally joined by links 7 and 9. Each holder has a set of rollers 4,5, for vertical and horizontal guiding on tending to the outlet end 12A. Cam means (not shown) can be provided at the inlet and outlet ends 11A, 12A to move the film clips of the holders 3 to a closed film gripping position at the inlet 11A for movement of the film through the conveying passage and to an open position at the outlet end 12A to free the film.
FIG. 7 further shows the arrangement of crosshead X 1 for the pivot points 19 in the apparatus carrier body 41 mounted on a pedestal (not shown) and slidable in a transverse direction T--T on the pedestal by means of a sliding arrangement similar to the items 33A, 34A of FIG. 6, a threaded rod 42 again being provided to impart motion to the body 41. A support block 43 is movable on the body 41 in the direction L--L (i.e. out of the plane of the paper in FIG. 7) by virtue of the sliding dovetail guide 44, and the block 43 serves to support successive rail support members 45, 46 in such a manner that the rail support members are relatively pivotal. To this end, the rail support members 45, 46 carry respective connecting pieces 45A, 46A. Referring to FIG. 8, pieces 45A, 46A each include an arcuate flange segment 47, and these segments 47 surround a pin 48 mounted in the block 43, appropriate end spacing being present between the segments 47 to provide the desired maximum angle of pivoting between the rail support members 45, 46. To provide stability, a connecting arm 49 links the members 45, 46. Further, by the segments 47, changing geometry conditions created by arcuate bending of the rail 2A at the pivot can be satisfactorily accommodated. The above joint arrangement is in fact covered by the applicants U.K. Patent Application No. 8809655.7 filed 23 April 1988.
Suitable extension joints for use in the arms 10A, 12A (and also in arm 11C) are illustrated in FIGS. 9A and 9B. Thus FIG. 9 shows a simple stepped overlapping plate arrangement 51, 52, while in FIG. 9B overlapping plate portions 53, 54 of L shaped cross section are present with the portions 53, 54 being linked together by a pin 55 located in an elongate slot 56. Further variations are possible, such as for example a multi-part telescopic construction.
FIG. 10 shows part of a prior art stenter arrangement where the feed and return runs, 9, 10 are moved in parallel over width adjustment range R from a maximum (full line) to a minimum (dashed line), the return run 10 in this case being outwith the chambers 16, 17. It will be evident that for the provision of a reasonable range R the sprocket 11B (12B) will require to be of relatively large diameter D if the runs 9, 10 are not to foul the side wall of chamber 16 (17). By having the return run 10 set in the present arrangement, sprockets 11B, 12B of relatively smaller diameter can be used.
Entry and outlet rail structures for the embodiments of FIGS. 11 and 12 are generally similar to the arrangements at FIG. 2-5. In the stenter apparatus shown in FIG. 11, the return run 10 passes on the outside of the heating chamber 16 and the crystalling or cooling chambers 17. The end portions 10A, 10B of the run 10 adjacent the sprockets 11B, 12B are again pivot to permit lateral adjustment of the feed run 9, and the outer run portion from 20A to 20B is fixed in position. Unlike the embodiment of FIG. 1, however, the last intermediate crosshead X N is located outside the final chamber 17 at the endwall thereof, and in this case the arm 10B is pivotal at the final intermediate crosshead X 1 .
FIG. 12 shows a further embodiment similar in which the arm 10A is pivotal at the first intermediate cross-head X 1 . | Stenter apparatus for stretching a web to produce a relatively thin film comprises two transversely spaced endless chains one the mirror image of the other relative to the stenter center line (C--C), each chain comprising an inner feed run (9) and an outer return run (10) mounted on supports. Each endless chain is constituted by film clip holders (3) and the chain pases around end sprockets (11B, 12B). The present invention provides a means for lateral adjustment of the feed runs (9) comprising adjustment means for lateral movement of the feed run support relative to the return run support and pivoting portions (10A, 10B) in the outer run support adjacent the end sprockets (11B, 12B) to enable said lateral movement of the feed run. Consequently a major portion of the outer run support does not require to have lateral movement and can be fixed in position and this provides economies in the construction. Further, end sprockets (11B, 12B) of smaller diameter can be used. | 3 |
BACKGROUND OF THE INVENTION
Processes for the preparation of polyesters by polycondensation of bivalent phenols with chlorides of aromatic dicarboxylic acids, like phthalac acid, isophthalic acid and terephthalic acid, have been known for a long time. Various bivalent phenols, such as hydroquinone, resorcinol, dioxydiphenyl-methane, 2,2-bis-(4-hydroxyphenyl)-propane, phenolphthalein, and others can be used. All these polyesters have a rather low temperature stability, so that they can not be used at temperatures of for example, 300° C. and above.
A similar process for the preparation of polyesters which can withstand temperatures of 300° C. is also known. According to this process, 9,9-bis-(4-hydroxyphenyl)-fluorene is used as a bivalent phenol, either alone or in admixture with other bivalent phenols. These polyesters can be prepared both by two-phase-boundary surface-condensation and by polycondensation in high boiling solvents, as well as by low temperature polycondensation in chlorinated hydrocarbons by using a suitable HCl-acceptor. If 9,9-bis-(4-hydroxyphenyl)-fluorene is used primarily in these syntheses, polyesters are obtained whose softening temperature is, any case, above 300° C. and with regard to which a true softening temperature below the decomposition temperature no longer takes place. This is particularly the case when 9,9-bis-4-(hydroxyphenyl)-fluorene is used exclusively as a phenol component.
By partial substitution of 9,9-bis-(4-hydroxyphenyl)-fluorene by other bivalent phenols, such as 2,2-bis-(4-hydroxyphenyl)-propane, the processing possibilities can generally be extended. For example, with a 50% use of 2,2-bis-(hydroxyphenyl)-propane in the phenol component, polyesters are obtained from which homogeneous molded articles can already be obtained at substantially lower temperatures than is the case with polyesters produced by the sole use of 9,9-bis-(4-hydroxyphenyl)-fluorene.
In judging the degree of flammability of plastics, it is customary to measure the so-called "limiting oxygen index" (LOI) according to U.S. specification ASTM D 2863, where the minimum concentration of oxygen in a streaming oxygen-nitrogen mixture is determined at which a combustion with the formation of flames can just be maintained in a standardized measuring arrangement. It has been found that the highest LOI value is obtained in the above-mentioned polyesters produced with 9,9-bis-(4-hydroxyphenyl)-fluorene, when the polyesters are produced almost exclusively with the use of this phenol. Depending on the chemical composition, type and shape of the test piece, LOI values of from 35 to 38% can be obtained. A small portion of 10 mol% 2,2-bis-(4-hydroxyphenyl)-propane in the phenol component results in a reduction of the LOI values to from 31 to 34% in the polyesters produced.
But even LOI values of 35-38% are at the lower limit of the admissible values for particularly critical application where a particularly low flammability is required, such as in airplanes. Other high-temperature resistant plastics, such as bis-maleimides or polyimides frequently have substantially higher LOI values, namely up to about 48%. However, during thermal decomposition of these plastics, toxic nitrogen compounds are formed, which sets certain limits to their use in the interior decoration of airplanes and other vehicles used for human transportation.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a process for the preparation of aromatic polyesters.
It is also an object of the invention to provide aromatic polyesters characterized by high temperature stability and resistance to flammability.
It is further an object of the invention to provide aromatic polyesters which show a low development of heat and a high char yield in combustion.
These and other objects of the invention will become more apparent from the description below.
DESCRIPTION OF THE INVENTION
This invention is a response to the problem of providing a process for the production of suitable aromatic polyesters by polycondensation of bivalent phenols with chlorides of aromatic dicarboxylic acids, such as isophthalic acid and/or terephthalic acid, where the phenol component consists at least primarily of 9,9-bis-(4-hydroxyphenyl)-fluorene, where the polyesters produced have higher LOI values than the known polyesters of this type, and where higher values of the inherent viscosity can be achieved under similar process conditions.
According to the invention, the problem is solved by using for the polycondensation
(a) a phenol component comprised primarily of 9,9-bis-(4-hydroxyphenyl)-fluorene;
(b) from about 50 to 92 mol percent, based on the number of moles of component (a), of acid chlorides of isophthalic and/or terephthalic acid; and
(c) from about 8 to 50 mol percent, based on the number of moles of component (a), of one or more compounds containing phosphorous in the tri- and/or pentavalent state, said compounds having the formula ##STR1## wherein X represents a halogen atom, preferably a chlorine atom, and R represents a halogen atom, preferably a chlorine atom, or an alkyl or alkoxy radical having from 1 to 6 carbon atoms or an aryl or phenoxy radical having from 6 to 10 carbon atoms.
The phenol component (a) will comprise primarily, i.e., from about 50 to 100 mol percent of 9,9-bis-(4-hydroxyphenyl)-fluorene. Other suitable bisphenols useful in component (a) include 2,2-bis-(4-hydroxyphenyl)-propane, as well as other bisphenols known to those skilled in the art.
Component (b) can be in the form of acid halides of isophthalic acid and/or terephthalic acid such as the chlorides. Advantageously, the mixture for the polycondensation comprises from 75 to 90 mol percent of component (b) and from 10 to 25 mol percent of component (c).
Preferably, component (c) comprises a mixture of phosphorous containing compounds. It is especially advantageous to employ a mixture of a compound having three halogen, preferably chlorine, atoms and one or more other compounds having two halogen, preferably chlorine, atoms. Suitable phosphorous containing compounds include phosphorous oxychloride and phenylphosphine oxide dichloride.
EXAMPLES
To further illustrate the invention, two synthesis examples representative of the state of the art and two examples according to the invention are presented below. In these examples, the synthesis were carried out by low-temperature polycondensation of the monomers dissolved in 1,2-dichloroethane in the presence of triethylamine as an HCl acceptor. A three-necked flask of ten liter capacity equipped with a stirrer, dropping funnel, and thermometer was used as a reaction vessel.
Characteristic properties of the polyesters produced in each synthesis were then measured and the results are set-forth in tabulated form below to illustrate the progress achieved with the process according to the invention. These properties are, respectively, the LOI values, determined according to the above-mentioned ASTM D 2863, as measured on a film of 0.125 mm thickness; the char yield in a nitrogen atmosphere at 800° C.; the "inherent viscosity"; and the softening and decomposition temperatures. The inherent viscosity (η inh) is defined by the relation ##EQU1## where η rel represents the relative viscosity and C represents the polymer concentration in the solvent during the viscosity measurement. A value of C=0.5% was maintained in the measurements.
EXAMPLE 1
The reaction vessel was charged with a Reaction Mixture A consisting of
315 g (0.9 mole) of 9,9-bis-(4-hydroxyphenyl)-fluorine
22.8 g (0.1 mole) of 2,2-bis-(4-hydroxyphenyl)-propane
280 ml (2 moles) of triethylamine
4000 ml of 1,2-dichloroethane
Reaction Mixture A was dissolved and then tempered to about 30° C.
To carry out the synthesis, a solution of Reaction Mixture B, consisting of
101.5 (0.5 mole) of isophthaloyl chloride
101.5 (0.5 mole) of terephthaloyl chloride
1000 ml of 1,2-dichloroethane
was added slowly dropwise for one hour to Reaction Mixture A in the reaction vessel, and the combined reaction mixture was allowed to react for another hour. The combined reaction mixture, which then contained the polymer in a dissolved state, was then added to a precipitating vessel under intensive stirring to 10 ml methanol, with the polymer precipitated in easily filtrable form. The precipitate was recovered, washed chloride-free first with methanol and then with water, and fially dried at 130° C. in the drying cabinet.
The yield of the aromatic polyester formed was 447 g (98% of theory). Very good films of this polyesters were obtained from a solution in dichloroethane.
Other important properties are shown below in Table I.
EXAMPLE 2
In accordance with the procedure set forth in Example 1, an aromatic polyester was formed. Reaction Mixture A consisted of:
350 g (1 mole) of 9,9-bis-(4-hydroxyphenyl)-fluorene
280 ml (2 moles) of triethylamine
4000 ml of 1,2-dichloroethane
and Reaction Mixture B consisted of:
101.5 (0.5 mole) of isophthaloyl chloride
101.5 (0.5 mole) of terephthaloyl chloride
1000 ml of 1,2-dichloroethane.
The yield of the aromatic polyester formed was 475 g (99% of theory). Film formation from a solution in dichloroethane was very good. Other properties are shown below in Table I.
EXAMPLE 3
A phosphorus aromatic polyester was produced according to the process of the invention according to the process and reaction conditions of Example 1. Reaction Mixture A consisted of:
350 g (1 mole) of 9,9-bis-(4-hydroxhphenyl)-fluorene
280 ml (2 moles) of triethylamine
4000 ml of 1,2,-dichloroethane
and Reaction Mixture b consisted of:
91.5 g (0.45 mole) of isophthaloyl chloride
91.5 g (0.45 mole) of terephthaloyl chloride
15.5 g (0.1 mole) of phosphorus oxychloride
1000 ml of 1,2-dichloroethane
The yield was 458 g (97% of theory). Film formation from a solution in dichloroethane was very good. Other properties are set forth in Table I below.
EXAMPLE 4
For the production of another phosphorous aromatic polyester according to the process of the invention, the same process and reaction conditions as in Example 1 were used. Reaction Mixture A consisted of:
350 g (1 mole) of 9,9-bis-(4-hydroxyphenyl)-fluorene
280 ml (2 moles) of triethylamine
4000 ml of 1,2-dichloroethane
and an Reaction Mixture B consisted of:
81.2 g (0.4 mole) of isophthaloyl chloride
81.2 g (0.4 mole) of terephthaloyl chloride
39 g (0.2 mole) of phenylphosphine oxide dichloride
1000 ml of 1,2-dichloroethane.
The yield was 458 g (98% of theory). Film formation from a solution in dichloroethane was very good. Other properties are set forth in Table 1 below.
The properties of the aromatic polyesters prepared in Examples 1 to 4 were evaluated according to procedures described above, and the results are set forth in the following table:
TABLE I______________________________________Example: 1 2 3 4______________________________________Phosphorus content -- -- 0.58 1.23(12% by weight)Inherent viscosity (ηinh) 0.60 0.52 0.68 0.50LOI (%) 31 35 38 40Char-yield (%) 52 57 60 60Softening temperature (°C.) 330 350 >350 >350Decomposition temperature (°C.) 480 490 500 500______________________________________
With regard to Examples 1 and 2, which represent the state of the art, it should be pointed out that the 0.1 mole of 2,2-bis-(4-hydroxyphenyl)-propane used in Example 1 in addition to the 0.9 mole of 9,9-bis-(4-hydroxyphenyl)-fluorene, brought no noticeable improvement or extension of the processing possibilities in the resulting polymers. Furthermore, as can be seen from Table I, despite the higher inherent viscosity of 0.6 achieved in the above-described synthesis charge in Example 1, as compared to 0.5 in Example 2, there is clear drop of the LOI values, namely, from 35 to 31%, and of the char yield, from 57 to 52%.
The process according to the invention, represented by Examples 3 and 4, brings advantages which manifest themselves in the improved properties of the polyesters formed. First, an increase in the char yield was achieved in the polyesters with the use of phosphorous compounds according to the invention. As it can be seen further from the table, and as it was verified by additional tests, the LOI values increase with rising phosphorous content. Other properties of the polyesters obtained depend, however, greatly on the type and form of the incorporation of the phosphorus in the polymers. Thus, with the use of phosphorus oxychloride (see Example 3), the inherent viscosity (η inh) of the polyester increased greatly with its rising mol % portion in Reaction Mixture B, particularly with a portion of more than 10 mol %. While 10 mol % phosphorus oxychloride brings only an increase to η inh to 68, the use of 15 mol % resulted in η inh of about 2. With this mixture, however, the solubility of the polyester produced is too low already to be able to cast usable films from the solution.
This behavior was probably due to the fact that the use of phosphorus oxychloride, which contains three reactive chlorine atoms, results in branchings and partial cross-linkages, particularly with higher percentages in the polymer chain, which manifests itself in a higher viscosity. In practice, this would have the advantage that an optimum viscosity could be obtained with the use of an adequate amount of phosphorus oxychloride but the disadvantage that the incorporation of a higher phosphorus content in the polyesters is not possible with phosphorus oxychloride alone.
This viscosity increase did not appear in Example 4 with the incorporation of phenylphosphine-oxide dichloride, a phosphorous compound with two reactive chlorine atoms, as will be readily understood. Here, a certain molar percentage of phthaloyl chloride was substituted during the polycondensation by phenylphosphine-oxide dichloride. The chain structure of the polyester produced was preserved, and a relatively high portion of phosphorus in the synthesis described in Example 4, it was 1.23% by weight, can be incorporated in the polyester.
To combine the advantages of the batch in Example 3, namely, the possibility of adjusting an optimum viscosity, and those of the batch in Example 4, it is furthermore possible within the framework of the invention to use as phosphorus compounds in Reaction Mixture B a mixture of phosphorus oxychloride and a compound or compounds which have each only two reactive chlorine atoms, such as phenylphosphine oxide dichloride.
The preceding specific embodiments are illustrative of the practice of the invention. It is to be understood, however, that other expediates known to those skilled in the art, or disclosed herein may be employed without departing from the spirit of the invention or the scope of the appended claims. | A process for the preparation of aromatic polyesters which are characterized particularly by high-temperature stability and difficult inflammability and which show, in addition, a low development of heat and a high char yield in combustion. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/411,429, filed Nov. 8, 2010, and claims foreign priority to French Patent Application No. FR 1059302, filed Nov. 10, 2010. These applications are herein incorporated by reference in their entireties.
BACKGROUND
[0002] During the implantation of a glenoid component of a shoulder prosthesis, the surgeon must prepare the glenoid of the patient in order to bear and immobilize the glenoid component of the shoulder prosthesis. To that end, the surgeon generally uses a motorized or manual milling machine. The milling machine comprises a burr whose proximal side is secured to a driving grip. The distal surface of the burr has reliefs, such as teeth, blades, and/or tips. The burr rotates or oscillates around its central axis in order to shave the bone material making up the glenoid and hollow, cut into, and/or grate the bone material until the glenoid is given a shape adapted to the prosthetic glenoid component to be implanted. For example, the burr hollows a bowl-shaped cavity in the glenoid in which a dedicated portion of the prosthetic glenoid component is housed in a substantially complementary manner. The bowl-shaped cavity may be a hemisphere or another concave cavity.
[0003] Furthermore, one potentially significant parameter for lasting stability of a prosthetic glenoid component relates to the proper positioning of that component on the glenoid. Thus, during surgical operations aiming to implant a glenoid component, an orthopedic guide pin, which may be a rod, is pushed partially into the glenoid at a predetermined point and in a predetermined direction. In that manner, the longitudinal part of said rod protrudes from the glenoid and may be used by the surgeon to guide and manipulate different ancillaries. For example, particular bone preparation ancillaries for the glenoid are axially engaged around the guide pin and then slid along said pin.
[0004] In particular, the surgeon has milling machines, like those mentioned above, in which the burr includes a hub with a central through bore that is dimensioned to axially receive the guide pin. During a surgical operation, after having placed the guide pin, the surgeon axially slips the proximal end of the pin into the central bore of the burr and then slides said burr and its proximal sleeve along the guide pin towards the glenoid until the distal surface of the burr is pressed against the glenoid. Burrs with a central hub may also be referred to as “cannulated burrs.” By rotating or oscillating the burr around the guide pin, the glenoid is milled precisely, in that the milling is well positioned relative to the glenoid due to the cooperation between the central hub of the burr and the guide pin.
[0005] However, the use of cannulated burrs poses implementation difficulties related to the presence of soft tissues around the glenoid as well as the proximity of the humeral head of the operated patient. It is therefore often necessary to place spacers to widely expose the glenoid in order to bring the glenoid longitudinally closer to the pin and avoid interference between the soft tissues and the burrs slid along the guide pin towards the glenoid. It is also often necessary to greatly displace the humeral head, or even resect the humeral head. In some cases, this procedure has the possibility of resulting in trauma and scars that may be significant for the patient.
SUMMARY
[0006] Embodiments of the present invention relate to an orthopedic milling machine for bone preparation, in particular glenoid preparation, and to a surgical method for preparing a bone, in particular a glenoid, by milling the bone using a milling machine.
[0007] Some embodiments of the present invention include an orthopedic burr that is easier for the surgeon to use and that is less traumatic for the patient. Specifically, those embodiments relate to an orthopedic milling machine for bone preparation, in particular glenoid preparation, having a burr that includes a hub. The hub includes an axial bore for receiving an orthopedic guide pin and the hub delimits a lateral passage slot for the guide pin. The slot emerges substantially radially from the bore through the hub.
[0008] Embodiments of the present invention also relate to a surgical method for preparing a bone, in particular a glenoid, by milling, wherein:
[0009] a bone to be milled is exposed,
[0010] an orthopedic guide pin is placed in the bone,
[0011] a burr is positioned near the guide pin, the burr including a hub provided with a bore that can receive the guide pin and that delimits a lateral passage slot for the guide pin, the slot emerging substantially radially from the bore,
[0012] the burr is brought laterally closer to the guide pin so that the guide pin is engaged radially through the slot until it reaches the inside of the bore, and
[0013] the burr is driven around the pin to mill the bone.
[0014] In those embodiments, the burr is brought laterally closer to the orthopedic guide pin, so as to bring the burr opposite a bone to be milled. Specifically, the burr is not brought frontally relative to said bone, but instead approaches laterally thereto. In this way, in the case of a glenoid milling machine, the burr can be slid or inserted between the patient's humeral head and shoulder blade until the burr is centered with the guide pin, without having to distract the patient's shoulder too greatly, or without having to move the soft tissues surrounding the glenoid away over the entire periphery thereof. To achieve such centering, the guide pin passes radially through the wall of the hub, which is made possible according to some embodiments by engaging the guide pin through a slot of the hub, dimensioned to that end. Thus, the burr may be placed on the bone, in particular on the glenoid, in a simplified and minimally invasive manner while still being able to mill the bone precisely using the burr and the guide pin. In practice, the actuation of the burr, for example rotating or oscillating the burr around the axis of its hub, can either be motorized or manual; in both cases, the hub of the burr can be coupled to an ad hoc driving mechanism that is slid axially around the guide pin.
[0015] Releasing the burr according to embodiments of the invention may be done just as easily, by moving it laterally to the glenoid so as to disengage its hub from the guide pin, via the slot of the hub.
[0016] Some embodiments include additional features that may be used individually or in combination, such as:
[0017] the burr includes a milling body, which is provided with bone etching reliefs and which extends transversely to the hub and outwardly surrounds the periphery of the hub at least in part, while leaving the opening of the slot open, radially opposite the bore;
[0018] the milling body extends all around the hub and includes both a crown, radially distant from the hub, and lugs that connect the hub and the crown in a substantially radial direction and that are distributed around the hub;
[0019] the slot extends, radially opposite the bore, in a free volume delimited between two consecutive lugs around the hub;
[0020] the crown delimits a lateral passage for the guide pin, said passage connecting said free volume and the outer peripheral surface of the crown;
[0021] the passage and the slot are situated substantially aligned in a direction radial to the axis of the hub;
[0022] the edges of the passage are inclined by at least 30° relative to a direction radial to axis X-X of the hub;
[0023] the crown is uninterrupted around the entire periphery thereof;
[0024] one of the lugs delimits an opening for laterally receiving the guide pin, said opening connecting the outer peripheral surface of the crown and the slot;
[0025] the milling body extends over only a peripheral portion of the hub, outside of which the slot is situated; and/or
[0026] the milling machine also includes mechanisms for driving the burr, which are adapted to be simultaneously engaged around the guide pin and coupled to the hub in order to drive the burr around the axis of its hub.
[0027] 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, which shows and describes illustrative embodiments of the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of a first embodiment of a burr of a milling machine.
[0029] FIG. 2 is an elevation view along arrow II of FIG. 1 .
[0030] FIG. 3 is a perspective view of the burr of FIGS. 1 and 2 , along with a glenoid to be milled and a guide pin placed in the glenoid.
[0031] FIG. 4 is a perspective view of the burr of FIGS. 1 and 2 , along with a glenoid to be milled and a guide pin placed in the glenoid, in which the guide pin passes through a passage in the burr.
[0032] FIG. 5 is a perspective view of the burr of FIGS. 1 and 2 , along with a glenoid to be milled, a guide pin, and a sleeve, in which the guide pin resides in a bore in the burr and the sleeve is placed over the guide pin.
[0033] FIG. 6 is a perspective view of the burr of FIGS. 1 and 2 , along with a glenoid to be milled and a sleeve, in which the sleeve is coupled to the burr.
[0034] FIG. 7 is an elevation view of a burr according to embodiments of the present invention.
[0035] FIG. 8 is an elevation view of a burr according to embodiments of the present invention.
[0036] FIG. 9 illustrates a perspective view of a burr according to embodiments of the present invention.
[0037] FIG. 10 illustrates an elevation view of the burr of FIG. 9 along arrow X of FIG. 9 .
[0038] FIG. 11 illustrates a perspective view of a burr according to embodiments of the present invention.
[0039] FIG. 12 is an elevation view of the burr of FIG. 11 along arrow XII of FIG. 11 .
[0040] While the invention is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0041] FIGS. 1 to 6 show embodiments of a milling machine 1 that include a burr 10 , shown alone in FIGS. 1 and 2 , and mechanism 20 for driving the burr 10 , shown in FIGS. 5 and 6 . The mechanism 20 for driving the burr may include a sleeve 21 , which is described in more detail below, in light of FIGS. 5 and 6 .
[0042] According to the embodiments shown in FIGS. 1 to 3 , the burr 10 has a discoid shape with a circular base, centered on an axis X-X. More specifically, the burr 10 includes two concentric annular portions, e.g. an inner hub 11 and an outer crown 12 , both centered on axis X-X. The hub 11 and the crown 12 are rigidly connected to one another by six individually identical lugs 13 , which each extend lengthwise from the hub 11 in a direction substantially radial to axis X-X and which are distributed substantially uniformly around the hub. These lugs 13 need not be strictly rectilinear, but may have a slight, lengthwise curve. The lugs 13 may have longitudinal profiles of various shapes and sizes, and the embodiments described below are non-limiting examples.
[0043] On their distal surface, e.g., the surface facing the reader looking at FIGS. 1 and 2 , the lugs 13 are each provided with a blade 14 that runs over the entire length of the lug 13 . The blades 14 are designed to etch the bone matter and thus to mill the bone matter when the burr 10 is rotated around its axis X-X. To that end, each blade 14 is, for example, provided with a cutting edge extending over the distal end rim of the corresponding lug 13 . In some embodiments, each of the blades 14 do not extend strictly in a plane perpendicular to axis X-X but are curved to match a spherical enclosure that is curved towards the distal side of the burr 10 and the axis X-X. In other words, each lug 13 will arch up and away from the crown 12 towards the axis X-X with a specific curvature that may substantially correspond to the curvature of a sphere. In this way, when the burr 10 is rotated around axis X-X, the blades 14 are able to hollow out a bowl-shaped cavity in the bone matter when revolving around the axis X-X. In some embodiments, the bowl-shaped cavity is a hemisphere or another concave cavity.
[0044] Bone etching reliefs may include components other than the blades 14 , such as spurs, teeth, tips, and the like. Furthermore, by way of one alternative not illustrated, such bone etching reliefs can be provided on all or part of the distal surface of the crown 12 , as well as on all or part of the distal surface of the hub 11 . In other words, more generally, the crown 12 and the lugs 13 form, at least in part, a milling body that is arranged coaxially and transversely to the hub 11 and that can assume various forms.
[0045] Given its angular shape, the hub 11 inwardly delimits a bore 15 that is centered on the axis X-X and passes axially all the way through the hub 11 , thereby emerging on the distal surface of the hub 11 , as shown in FIGS. 1 and 2 , and on the proximal surface of the hub 11 , as shown in FIG. 3 . As described below, the bore 15 may be inwardly tapped so as to accept a threadable connection with a driver.
[0046] As shown in FIGS. 1 to 3 , the annular wall 50 of the hub 11 , which delimits the bore 15 , is slotted over its entire axial dimension in only a portion of its periphery, according to embodiments of the present invention. In other words, the annular wall 50 of the hub 11 delimits a transverse slot 16 that connects the distal and proximal surfaces of the hub 11 in the direction of axis X-X and that connects the bore 15 and the outer peripheral surface of the hub 11 , for example in a direction radial to axis X-X. In a plane perpendicular to axis X-X, the edges 52 , 54 of the slot 16 are remote from one another with a spacing denoted e in FIG. 2 . In the embodiments illustrated in FIGS. 1 to 3 , the edges 52 , 54 of the slot 16 form parallel planes that are also substantially parallel to a diametric plane of the burr 10 passing through axis X-X. By way of one alternative embodiment not illustrated, the aforementioned edges 52 , 54 of the slot 16 can have a certain curve, in particular with a profile curved in a plane perpendicular to axis X-X, as long as said edges 52 , 54 maintain the spacing e between them in a plane perpendicular to axis X-X.
[0047] As illustrated in FIGS. 1 to 3 , the slot 16 may be formed in a portion of the hub 11 that is situated along the periphery of the hub 11 between two consecutive lugs 13 , more specifically between the ends 56 , 58 of said consecutive lugs 13 , facing axis X-X. In this way, the slot 16 opens radially opposite its opening to the bore 15 into a free volume V of the milling body of the burr 10 . The free volume V is delimited by the two aforementioned consecutive lugs 13 and by the peripheral portion of the crown 12 that connects the ends of the aforementioned consecutive lugs 13 , opposite axis X-X. Moreover, within in the aforementioned portion of the crown 12 is a transverse passage 17 that passes radially through the crown 12 , thereby connecting the free volume V and the outer peripheral surface of the crown 12 . This passage 17 is therefore similar to a through slot made radially through the crown 12 . For reasons specified below, this passage 17 may be arranged to be substantially aligned with the slot 16 in a direction radial to axis X-X, as shown in FIG. 2 .
[0048] The opposite edges 60 , 62 of the passage 17 are separated from one another in a plane perpendicular to axis X-X, with a relative spacing substantially equal to the spacing e between the edges of the slot 16 .
[0049] One example of the use of the burr 10 will now be presented in light of FIGS. 3 to 6 , in the context of a surgical operation aiming to prepare the glenoid G of a shoulder blade S in order to implant a glenoid component of a shoulder prosthesis.
[0050] As shown in FIG. 3 , before using the burr 10 an orthopedic guide pin 30 is placed in the glenoid G. That guide pin 30 consists of a rigid rod with a small transverse section that is, on a distal end portion, pushed into the bone material of the glenoid G. In practice, the tip for pushing the pin 30 into the glenoid G, as well as the direction of that pushing relative to the glenoid, are imposed by the surgeon, who places the pin 30 in accordance with a preferred implantation axis of the aforementioned prosthetic glenoid component. In some embodiments, the surgeon will use the guide pin 30 during surgical operation with several surgical ancillaries. The placement of the guide pin 30 is a well-known operation in orthopedic shoulder surgery, and it will not be described here in further detail.
[0051] As shown in FIG. 3 , the surgeon brings the burr 10 close the glenoid G to be milled, not by sliding the bore 15 axially around the guide pin 30 but by moving the burr 10 laterally to the guide pin 30 following a plane perpendicular and/or askew to said pin. This lateral approach of the guide pin 30 by the burr 10 is indicated by an arrow F 1 in FIG. 3 . This lateral approach makes it possible to slide the burr 10 between the shoulder blade S and the humeral head associated with said shoulder blade (not shown), while the distal surface of the burr faces the shoulder blade. In this way, it is not necessary for the surgeon to distract the shoulder joint too much, thereby limiting the trauma to that joint.
[0052] As visible by comparing FIGS. 3 and 4 , the lateral approach to the guide pin 30 by the burr 10 is continued until the crown 12 of the burr 10 comes into the immediate vicinity of the guide pin 30 , more specifically the intermediate portion 64 of said guide pin 30 , emerging from the glenoid G. The movement of the burr 10 is then continued, as indicated by arrow F 2 in FIG. 4 , so as to transversely engage the guide pin 30 through the passage 17 in a direction radial to axis X-X.
[0053] For the guide pin 30 to be able to pass through the crown 12 via the passage 17 , the spacing between the edges 60 , 62 of said passage 17 are at least equal to, or slightly larger than the diameter of the guide pin 30 , according to embodiments of the present invention. After crossing the passage 17 , the guide pin 30 is positioned inside the crown 12 , extending axially through the free volume V.
[0054] Still while continuing the lateral approach to the guide pin 30 with the burr 10 , the surgeon brings the hub 11 closer to the intermediate portion 64 of said guide pin 30 , until said intermediate portion 64 of the guide pin 30 is engaged through the slot 16 , as indicated by arrow F 3 in FIG. 5 . According to the same considerations as before regarding the passage 17 , it is understood that the spacing e between the edges 52 , 54 of the slot 16 is sufficient, compared to the diameter of the pin 30 , to allow said guide pin 30 to pass through the wall of the hub 11 , via the slot 16 , until the guide pin 30 is located inside the bore 15 , in particular in a configuration coaxial to said bore 15 , as shown in FIG. 5 . In other words, in that configuration, the axis X-X of the burr 10 is combined with the central axis of the guide pin 30 . Thus, it will be noted that, in return for the lateral approach described above in reference to FIGS. 3 to 5 , the burr 10 has been moved until it is coaxial with the guide pin 30 without needing to axially engage said burr 10 from the proximal end of the guide pin 30 . This lateral approach allows the surgeon to limit the extent of the surgical incisions in the soft tissue surrounding the glenoid G, in that those soft tissues only need to be incised and spaced apart over about half of the periphery of the glenoid G.
[0055] As shown in FIGS. 5 and 6 , a tubular sleeve 21 is configured to slide around the guide pin 30 while being axially engaged around said guide pin 30 from the proximal end thereof. The tubular sleeve 21 slides around the guide pin 30 , toward the burr 10 , as indicated by arrow F 4 in FIG. 5 . That sliding movement continues until the distal end 22 of the sleeve 21 reaches the burr 10 . The distal end 22 of the sleeve 21 is then mechanically coupled to the hub 11 . In some embodiments, that coupling is done by screwing the end 21 , threaded for that purpose, into the tapping of the bore 15 . Other forms of mechanical coupling between the sleeve 21 and the hub 11 can be used in the context of the present invention.
[0056] During coupling operations, the surgeon may manipulate the burr 10 by gripping it by the proximal end of the hub 11 . For example, as shown in FIG. 5 , the proximal end of the hub 11 delimits two diametrically opposite flats 18 , shown in FIG. 5 , which allow the surgeon to firmly immobilize the burr 10 in rotation around axis X-X, in order to facilitate screwing of the end 22 of the sleeve 21 in the bore 15 . Furthermore, these flats 18 can be used by the surgeon, by themselves if necessary, in order to manipulate the burr 10 during all or each of the steps of its placement.
[0057] Once the sleeve 21 is secured to the burr 10 , as shown in FIG. 6 , said sleeve 21 is rotated around its central longitudinal axis, for example by connecting its proximal end to an ad hoc driving motor. The rotational movement imposed on the sleeve 21 is transmitted to the burr 10 such that the blades 14 shave the bone material making up the glenoid G and mill the bone material as mentioned above. Of course, rather than being motorized, the sleeve 21 can be driven manually.
[0058] The milling of the glenoid G by the burr 10 is thus guided by the guide pin 30 , inasmuch as said guide pin constitutes the application axis of the burr 10 on the glenoid G. Once the milling of the glenoid G is finished, the sleeve 21 is, after separating the sleeve 21 and the hub 11 , released by sliding the sleeve 21 along the guide pin 30 toward the proximal end of said pin. The surgeon then releases the burr 10 laterally from the guide pin 30 , making the intermediate portion of said guide pin successively pass through the slot 16 and the passage 17 , following a lateral movement opposite to that described in reference to FIGS. 3 to 5 .
[0059] FIG. 7 shows an alternative embodiment of the burr 10 , where elements similar to elements in the embodiments shown in FIGS. 1 to 6 bear the same references. This alternative embodiment differs from the embodiment of FIGS. 1 to 6 , for example, by the transverse passage provided through the crown 12 , said passage being referenced 17 ′ in FIG. 7 . More specifically, the passage 17 ′ differs from the passage 17 in that, unlike the passage 17 , its edges 60 ′, 62 ′ do not extend in planes parallel to a diametric plane of the burr 10 passing through axis X-X. Instead, those edges 60 ′, 62 ′ of passage 17 ′ are, in a plane perpendicular to said axis X-X, substantially inclined relative to a direction radial to said axis X-X. Thus, in a plane perpendicular to axis X-X, the line connecting the inner and outer ends of each of the edges 60 ′, 62 ′ of the passage 17 ′ form, with a direction radial to axis X-X, a non-zero angle α that is greater than or equal to 30°, or even 45°. In this way, the passage 17 ′ does not extend, between its openings on the outside of the crown 12 and on the free volume V, strictly in a direction radial to axis X-X but along a path inclined relative to said radial direction in comparison to the passage 17 . Having a passage 17 ′ oriented as shown in FIG. 7 results in less interference or gripping between the opening on the outside of the passage 17 ′ and elements outwardly surrounding the crown 12 when the burr 10 is rotated in the direction indicated by arrow R in FIG. 7 , i.e., in the direction opposite the incline α of the passage 17 ′ relative to the direction radial to axis X-X. In fact, the rear edge 62 ′ of the passage 17 ′ forms, with the outer peripheral surface of the crown 12 , an obtuse angle β, greater than or equal to 135°, which pushes elements that would enter the passage 17 ′ during the rotation of the burr 10 toward the outside of passage 17 ′. Such elements are, for example, the soft tissue surrounding the glenoid G. In other words, with the embodiment of FIG. 7 , the risks of the passage 17 ′ gripping or catching the soft tissue surrounding the glenoid during setting in rotation of the burr 10 in direction R are lower, compared to the embodiment of the burr 10 of FIGS. 1 to 6 . Advantageously, rather than being strictly planar, the edges 60 ′, 62 ′ of the passage 17 ′ have, in a cutting plane perpendicular to axis X-X, a curved profile that is curved in the direction opposite axis X-X. This reinforces the non-catching effect of the soft tissue that may be present around the crown 12 when the burr 10 is rotated in direction of rotation R.
[0060] It will be noted that the incline α of the passage 17 ′ relative to the direction radial to axis X-X means that its opening on the outside is offset, in a peripheral direction of the crown 12 , relative to its opening on the free volume V. Consequently, to place the burr 10 on the glenoid G, the burr must be moved in a different manner than the burr described in FIGS. 1 to 6 , in which the engagement of the guide pin 30 through the passage 17 and then the slot 16 more simply consists of a substantially rectilinear movement of the burr 10 relative to the guide pin.
[0061] FIG. 8 shows another alternative of the burr 10 of FIGS. 1 to 6 , in which the components of the burr that are similar to components in the embodiment of FIGS. 1 to 6 bear the same numerical references. The alternative of FIG. 8 differs from the burr of FIGS. 1 to 6 , for example, by the absence of the passage 17 . In other words, unlike the crown 12 , the crown 12 ″ of the burr 10 of FIG. 8 is uninterrupted over the entire periphery thereof. The absence of passage 17 facilitates the manufacture of the burr 10 but causes a slightly different use from that of the embodiment of FIGS. 1 to 6 . For example, inasmuch as the crown 12 ″ is not slotted, it is not possible to bring the guide pin 30 through the free volume V via a lateral approach of said guide pin 30 . Also, unlike what was described above in light of FIGS. 3 and 4 , the surgeon engages the guide pin 30 axially in the free volume V, e.g., axially engaging the proximal end of said guide pin between the successive lugs 13 delimiting said free volume V. Then, the surgeon slides the burr 10 along the guide pin 10 while the guide pin 30 extends through the free volume V, preferably while the guide pin is pressed laterally against the inner peripheral surface 66 of the crown 12 ″; in this way, the surgeon brings the burr 10 close to the glenoid G while keeping the burr 10 centric relative to the guide pin 30 , preferably as centrically as possible. In so doing, the surgeon can play on the incline of the burr 10 to get around the humeral head, as well as other organs of the patient, while limiting the extent of the incisions and spacing of the soft tissues surrounding the glenoid. Once the burr 10 is slid to the level of the intermediate portion of the guide pin 30 emerging from the glenoid 10 , the surgeon brings the hub 11 closer to the guide pin 30 laterally relative thereto, in a similar manner as previously described in light of FIG. 5 , so as to engage said intermediate portion of the guide pin 30 through the slot 16 until the bore 15 is made coaxial with the guide pin.
[0062] FIGS. 9 and 10 show a burr 110 representing an alternative embodiment of the burr 10 . Said burr 110 is in particular designed to be used with the sleeve 21 described above, within a milling machine similar to the milling machine 1 .
[0063] Similar to the burr 10 , the burr 110 includes an inner annular hub 111 , which is centered on axis X-X and inwardly delimits a through bore 115 , and a milling body that extends transversely around the hub 111 . This milling body includes an outer crown 112 and five lugs 113 . The lugs 113 connect the hub 111 and the crown 112 in a direction substantially radial to axis X-X and are distributed around that axis along the periphery of the hub 111 . Similarly to the lugs 13 of the burr 10 , the lugs 113 of the burr 110 include cutting blades 114 on their distal surfaces.
[0064] The lugs 113 differ from the lugs 13 in that, in a cutting plane perpendicular to axis X-X, they have a substantially rectilinear profile. Furthermore, unlike the lugs 13 that are all individually identical, the lugs 113 are broken down into a group of four identical lugs 113 . The remaining lug 113 ′ differs from the other lugs 113 by the presence of an opening 119 that passes all the way through the lug 113 ′ in the direction of axis X-X, thereby connecting the distal and proximal surfaces of said lug, and running over the entire radial dimension of the lug 113 ′, thereby connecting the inner and outer ends of said lug. More specifically, at the outer end of the aforementioned lug 113 ′, an opening 119 emerges on the outer peripheral surface of the crown 112 , while, at the inner end of said lug 113 ′, the opening 119 is extended by a slot 116 , functionally similar to the slot 16 , delimited through the annular wall of the hub 111 . As visible in FIG. 10 , in a plane perpendicular to axis X-X, the opening 119 fits into the rectilinear extension of the slot 116 , its opposite edges being separated from one another by a space substantially equal to the spacing e between the edges of the slot 116 .
[0065] The burr 110 is used in substantially the same way as the burr 10 : before coupling the hub 111 to the sleeve 21 that slides along the guide pin 30 , the burr 110 is brought closer to said guide pin 30 laterally to the intermediate portion thereof, so as to radially engage said intermediate portion of the guide pin 30 through the opening 119 and the slot 116 successively, until reaching the inside the bore 115 .
[0066] FIGS. 11 and 12 show an alternative burr 210 , according to embodiments of the present invention. In practice, similar to the burrs 10 and 110 , the burr 210 is coupled to the sleeve 21 within a milling machine similar to the milling machine 1 .
[0067] The burr 210 includes an annular hub 211 , centered on an axis X-X and functionally similar to the hub 11 or 111 of the burrs 10 or 110 .
[0068] The bur 210 differs from the burrs 10 and 110 , for example, by the overall shape of its milling body; in fact, this body extends over a peripheral portion of the hub 211 and consists of a crown portion 212 connected to the hub 211 by one or more radial lugs 213 . On its distal surface, the crown portion 212 is provided with an etching or toothing 214 for milling the glenoid bone matter. In some embodiments, the milling body of the burr 210 has a bulk that is globally much smaller than that of the milling body of the burrs 10 and 110 . It is thus understood that the burr 210 may be used to produce bone preparations on a smaller scale.
[0069] For balancing reasons, the burr 210 advantageously includes a counterweight 212 ′, which extends transversely from the hub 211 and which is arranged diametrically opposite the crown portion 212 .
[0070] Similarly to the hub 11 or 111 of the burrs 10 and 110 , the hub 211 of the burr 210 simultaneously delimits an inner bore 215 , centered on axis X-X, and a lateral slot 216 , which connects the inside of the bore 215 and the outside of the hub 211 in a direction radial to axis X-X. As visible in FIG. 12 , this slot 216 is situated along the periphery of the hub 211 outside the milling body, i.e., outside the portion delimited by the two lugs 213 in which the crown portion 212 extends. More specifically, in the embodiment shown in FIGS. 11 and 12 , the slot 216 extends in a direction radial to axis X-X that is arranged substantially at 90° to the diametric direction in which the crown portion 212 and the counterweight 212 ′ are opposite. As a non-illustrated alternative, the slot 216 can be situated in the same portion as the crown portion 212 and to connect to the free volume V between the two lugs 213 .
[0071] The use of the burr 210 is similar to that described above for the burrs 10 and 110 , in that the placement of the burr 210 on a glenoid to be milled, provided beforehand with the guide pin 30 , consists of bringing the burr 210 closer to said guide pin 30 laterally to the intermediate portion of said guide pin 30 so as to radially engage said intermediate portion of the guide pin through the slot 216 until it reaches the inside of the bore 215 .
[0072] Various arrangements and alternatives to the milling machine described above, in particular the burrs 10 , 110 and 210 , can also be included alone or in combination, including but not limited to one or more of the following characteristics and/or features:
[0073] by way of non-illustrated alternatives for the burrs 10 and 110 , their crown 12 , 12 ″, or 112 can be eliminated at one or more portions along their periphery, or over the entire periphery thereof, in particular for small burrs;
[0074] by way of non-illustrated alternatives for the burr 210 , the counterweight 212 ′ can be replaced by a toothed crown portion, symmetrical to the crown portion 212 relative to axis X-X;
[0075] rather than having a circular base, the milling body of the burrs 10 , 110 and 210 can be centered on axis X-X while having an oval or ovoid or multi-lobed base;
[0076] as mentioned above, the geometry of the cavity hollowed out by the burrs 10 , 110 and 210 in the bone material is not a necessary limitation of those embodiments; thus, in return for ad hoc arrangements of the distal surface of their milling body, these burrs can perform both a concave spherical activity as described above, or a convex spherical relief, a planar resection, a cavity with a spherical central region and a flat peripheral edge, and the like; and/or
[0077] embodiments of the invention can be applied to orthopedic milling machines intended to be used on bones other than the glenoid of a shoulder blade; thus, embodiments of the invention are for example applicable to milling the humerus or the bones of the hand or foot.
[0078] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof. | Embodiments of the invention include an orthopedic milling machine for preparing a glenoid bone. The milling machine uses a hub and a sleeve. The hub includes reliefs arranged to cut or mill the bone and the sleeve couples to the hub to transfer rotational motion to the hub. The hub has an axial bore sized to receive an orthopedic guide pin. The hub also has a lateral passage slot that allows the hub to move laterally towards the guide pin in order to place the guide pin within the axial bore. | 0 |
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